A wind turbine blade core material repair device and method of use thereof

Abstract

A wind power blade core material repairing device and a method thereof, comprising a moving device, the moving device sequentially sets a glue applying device, a bonding device and a heating device from front to back along a moving direction; the glue applying device comprises a glue applying device and a glue applying box arranged on the moving device, a glue nozzle of the glue applying device is inserted into the glue applying box, rotating plates are arranged on both sides of the glue applying box, and a positioning plate for inserting into a core material gap is arranged at the bottom of the rotating plate; the bonding device comprises a reel I for winding a hot melt cloth, and a reel III for leading out the hot melt cloth and sticking the hot melt cloth to the core material; and the heating device comprises a hot air gun, and an air outlet of the hot air gun faces downward. The device of the application is used to replace manual operation, greatly improves the maintenance efficiency, reduces the maintenance difficulty, ensures the quality of the core material gap filling, improves the core material repairing efficiency and the core material laying process efficiency, and shortens the blade forming time.

Description

Technical Field

[0001] This invention belongs to the field of wind turbine blade technology, specifically relating to a wind turbine blade core material repair device and its usage method. Background Technology

[0002] As a key component of wind turbine generators, wind turbine blades typically employ a "sandwich" core structure. This structure reduces weight while increasing strength and rigidity. During blade manufacturing, fiberglass cloth is first laid as the bottom layer, followed by a thicker core material in the middle, and finally, another layer of fiberglass cloth is laid on top. Laying the core material is time-consuming. Due to its thickness, hardness, and insufficient processing precision, mismatches and poor adhesion between core materials can occur during layering, resulting in excessively large gaps. After vacuum injection molding, these gaps can easily accumulate resin, affecting the blade's structural performance. Therefore, these gaps need to be repaired and filled to prevent their formation.

[0003] The current conventional method for repairing core material gaps involves adjusting the core material to ensure stable gaps, then cutting additional core material blocks to fit the gap dimensions, embedding these blocks into the gaps, and finally inspecting the repair. If the repair is unsatisfactory, further adjustments are made. However, because the core material blocks are manually cut by operators, they cannot perfectly match the gap dimensions, requiring multiple adjustments to achieve satisfactory filling. Furthermore, core material blocks may detach or shift after repair. This method results in low core material repair efficiency, inconsistent repair quality, and a significant impact on blade forming efficiency. Summary of the Invention

[0004] To address the technical problems of low efficiency, unstable repair quality, and high difficulty in manual operation in existing core material gap repair technologies, this invention provides a wind turbine blade core material repair device and its usage method.

[0005] The objective of this invention is achieved through the following technical solution. A wind turbine blade core material repair device according to this invention includes a moving device. The moving device is arranged sequentially from front to back along the moving direction as a glue applicator, a bonding device, and a heating device. The glue applicator includes a glue applicator and a glue applicator box mounted on the moving device. The glue applicator nozzle is inserted into the glue applicator box. Rotating plates are rotatably arranged on both sides of the glue applicator box, and a positioning plate for inserting into the gap between the core materials is provided at the bottom of the rotating plates. The bonding device includes a roller I for mounting and winding hot melt fabric and a roller III for leading out the hot melt fabric and applying it close to the core material. The heating device includes a hot air blower with its outlet facing downwards.

[0006] Furthermore, the front end of the moving device is provided with a guide wheel for engaging within the gap in the core material and for guiding the moving device.

[0007] Furthermore, the glue applicator is an electric glue applicator, and a glue cylinder is installed on the electric glue applicator, the glue cylinder containing expanding foam.

[0008] Furthermore, the glue dispensing box includes a top plate with glue dispensing holes for inserting glue nozzles, and rotating plates are rotatably arranged on both sides of the plate.

[0009] Furthermore, a lifting rod is vertically installed on the glue dispensing box, and the other end of the lifting rod is installed on the active telescopic device on the moving device.

[0010] Furthermore, the rotating plate has an L-shaped cross-section, with the bottom edges of the pair of rotating plates extending relative to each other, and a positioning plate disposed at the end of the bottom edge.

[0011] Furthermore, a baffle is rotatably provided at the rear end of the glue applicator, and a roller with the same rolling direction as the moving direction is provided at the lower end of the baffle.

[0012] Furthermore, the moving device is provided with a roller II that is parallel to roller III and roller I and is located between roller III and roller I to guide the hot melt fabric.

[0013] A method for using a wind turbine blade core material repair device includes the following steps:

[0014] Place the core material repair adhesive in the glue applicator of the glue applicator, fix the glue applicator on the moving device, and insert the glue nozzle of the glue applicator into the glue box at the same time;

[0015] A roll of hot melt fabric is placed on the spool I of the bonding device;

[0016] Identify the core material that needs repair, move the repair device to one end of the core material gap, insert the guide wheel on the moving device into the core material gap, insert the positioning plate of the glue box into the core material gap, press one end of the hot melt cloth onto the bottom of the roll III, and align the hot air outlet of the hot air blower with the core material gap.

[0017] Turn on the electric glue applicator to apply glue for repair. Fill the gaps in the core material with the glue through the glue applicator box. Guide the moving repair device with the guide wheels. The rollers on the glue applicator box flatten the core material repair glue. During the movement of the moving device, the hot melt cloth moves and unrolls, covering the already filled core material repair glue and the core material on both sides. Then, the hot air heater heats it to release the adhesiveness of the hot melt cloth, bonding it to the core material repair glue and the core material on both sides.

[0018] Compared with the prior art, the advantages of the present invention are: the use of the device of the present invention to replace manual operation greatly improves maintenance efficiency, reduces maintenance difficulty, and at the same time ensures the quality of core material gap filling. It eliminates the problems of insufficient core material processing precision, difficulty in repairing core material gaps and unstable repair quality caused by complex blade airfoils, improves the efficiency of core material repair and core material laying process, and shortens blade forming time.

[0019] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of an embodiment of a wind turbine blade core material repair device according to the present invention;

[0021] Figure 2 for Figure 1 A schematic diagram of the glue box.

[0022] [Attached image labels]

[0023] 1 core material, 1-1 core material gap;

[0024] 2-1 Support plate, 2-2 Support rod, 2-3 Rotating wheel, 2-4 Guide wheel, 2-5 Handrail;

[0025] 3-1 Glue applicator box, 3-2 Vertical plate I, 3-3 Horizontal plate, 3-4 Fastening bolt I, 3-5 Electric glue applicator, 3-6 Glue cylinder; among which, 3-1a Flat plate, 3-1b Hinge, 3-1c Rotating plate, 3-1d Positioning plate, 3-1e Rotating shaft, 3-1f Baffle, 3-1g Roller, 3-1h Lifting rod, 3-1i Glue applicator hole;

[0026] 4-1 Vertical plate II, 4-2 Roll I, 4-3 Roll II, 4-4 Roll III, 4-5 Hot melt fabric;

[0027] 5-1 Support ring, 5-2 Fastening bolt II, 5-3 Hot air blower. Detailed Implementation

[0028] 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 only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] An embodiment of the wind turbine blade core material repair device of the present invention, such as... Figures 1 to 2 As shown, the device includes a moving device, an adhesive applicator, an bonding device, and a heating device. The adhesive applicator, bonding device, and heating device are all mounted on the moving device and move with it. The adhesive applicator, bonding device, and heating device are arranged sequentially in the direction of movement of the moving device. The moving device travels along the core material gap 1-1 between the core materials 1. During this travel, the adhesive applicator applies core material repair adhesive into the core material gap 1-1. Subsequently, the bonding device lays hot-melt cloth 4-5 on the core material repair adhesive and on both sides of the core material 1 surface. The heating device then fixes the hot-melt cloth to the core material repair adhesive and the core material surface to prevent secondary movement of the core material.

[0030] In this embodiment, the moving device includes a support plate 2-1, a support rod 2-2 for mounting rotating wheels 2-3 on the support plate 2-1, and four rotating wheels 2-3 on the moving device for moving the support plate 2-1 onto the core material 1 to be repaired.

[0031] To facilitate the movement of the mobile device along the extending direction of the core material gap 1-1 and ensure smooth application of the core material repair adhesive, a guide wheel 2-4 is installed at the front end of the mobile device. When using the repair device, the guide wheel 2-4 is engaged within the core material gap 1-1, rolling within it. The guide wheel can roll on the bottom or side wall of the core material gap 1-1, guiding the mobile device to move along its extending direction. The guide wheel is mounted on a connecting rod hinged to the support plate. When the mobile device is not in operation, the guide wheel can roll on the ground or core material surface it traverses.

[0032] A handle 2-5 is provided on the mobile device, allowing the operator to move the repair device by pushing the handle 2-5. In other embodiments of the invention, the rotating wheel 2-3 of the mobile device can be connected to a drive device, such as an electric motor, to propel the mobile device forward. The motor can be automatically or manually controlled by a control device on the mobile device, thereby controlling the start, stop, and speed of the mobile device. Alternatively, the start, stop, and speed of the mobile device can be controlled by a remote control wirelessly connected to the control device. By controlling the speed of the mobile device, the amount of core material repair adhesive injected into the core material gap 1-1 can be controlled, thereby ensuring that the density of the core material repair adhesive matches the core material.

[0033] The glue application device includes a glue application box 3-1 and an electric glue applicator 3-5. The glue application box 3-1 is used to cooperate with the core material gap 1-1. The electric glue applicator 3-5 is connected to the glue application box 3-1 and applies the core material repair glue in the electric glue applicator into the core material gap 1-1 through the glue application box 3-1.

[0034] An electric glue applicator 3-5 is equipped with a glue cartridge 3-6, which delivers the core material repair glue from the glue cartridge 3-6 into the glue dispensing box 3-1. In this embodiment, the core material repair glue is a foaming adhesive, a polymer material that can foam rapidly; the electric glue applicator 3-5 can also be driven by other power sources, such as hydraulic pressure, to dispense the core material repair glue from the glue cartridge 3-6 into the core material gap 1-1.

[0035] In this embodiment, a vertical plate I3-2 is provided on the upper part of the support plate 2-1 of the mobile device, and a horizontal plate 3-3 is provided on one side of the vertical plate I3-2. A hole is provided on the horizontal plate 3-3, and an electric glue applicator 3-5 is vertically installed in the hole of the horizontal plate 3-3 and fixed by the fastening bolt I3-4 on the horizontal plate 3-3.

[0036] A glue applicator 3-1 is installed below the support plate 2-1 of the mobile device. The electric glue applicator 3-5 passes through the support plate 2-1 and its nozzle is connected to the glue applicator 3-1. The glue applicator 3-1 includes a top plate 3-1a with a glue applicator hole 3-1i for inserting the nozzle of the electric glue applicator. The nozzle and the glue applicator hole 3-1i are fitted with a clearance, allowing the glue applicator and the electric glue applicator 3-5 to move up and down relative to each other.

[0037] Hinges 3-1b are provided on both sides of the flat plate 3-1a, and rotating plates 3-1c are provided on the hinges 3-1b, so that the rotating plates 3-1c can be rotated on both sides of the flat plate 3-1a. A positioning plate 3-1d is provided at the bottom of the rotating plate 3-1c, and the positioning plate 3-1d is used to insert into the core material gap 1-1. When expanding foam is injected into the glue box 3-1 through the glue injection hole 3-1i, the expanding foam first enters between the rotating plate 3-1c and the positioning plate 3-1d. Under the expansion force of the expanding foam, the two positioning plates 3-1d rotate and come close to the two side walls of the core material gap 1-1, so that the expanding foam can smoothly enter and fill the core material gap 1-1, preventing the expanding foam from being injected outside the core material gap 1-1. The rotating plate 3-1c and the positioning plate 3-1d play a guiding and restricting role in the injection of expanding foam.

[0038] A lifting rod 3-1h is vertically installed on the upper part of the flat plate 3-1a. Multiple lifting rods can be installed, and the other end of the lifting rod 3-1h is installed on the support plate 2-1 of the moving device. The lifting rod can be raised and lowered by an active telescopic device such as a hydraulic cylinder or a pneumatic cylinder. The top of the lifting rod 3-1h is connected to the output shaft of the active telescopic device installed on the support plate. When the gap at a certain point on the core material 1 is repaired and it is necessary to move the repair device to another core material gap, in order to allow the repair device to move smoothly on the core material, the lifting rod 3-1h is pulled upward by the active telescopic device, which in turn pulls the glue box upward, causing the positioning plate to disengage from the core material gap 1-1. Then the repair device can be moved to another core material gap, or the repair device can be removed after all core material gaps have been repaired.

[0039] In this embodiment, the rotating plate 3-1c has an L-shaped cross-section, and the bottom edges of the pair of rotating plates 3-1c extend relative to each other. The positioning plate 3-1d is disposed at the end of the bottom edge. After the positioning plate 3-1d is inserted into the core material gap 1-1, the bottom edge of the rotating plate 3-1c abuts against the surface of the core material, limiting the insertion depth of the positioning plate 3-1d and preventing the positioning plate 3-1d from being inserted too deeply, which would affect the mating area between the foam and the inner wall of the core material gap 1-1.

[0040] During the movement of the mobile device, the surface of the core material 1 is usually uneven. To ensure that the positioning plate 3-1d is always inserted into the gap of the core material, and thus to ensure the guidance of the foam adhesive, the lifting rod 3-1h can adopt a passive telescopic device. For example, the lifting rod 3-1h can be divided into three parts: a sleeve, a spring, and a sliding rod. The top of the sleeve is fixed on the output shaft of the active telescopic device, and a blind hole is provided at its bottom. A spring is installed in the blind hole, and the top of the spring abuts against the bottom of the blind hole. The upper part of the sliding rod is slidably set in the blind hole and abuts against the other end of the spring. The lower part of the sliding rod is set on the flat plate 3-1a. Pressing the glue box downwards causes the bottom edge of the rotating plate 3-1c to press against the surface of the core material 1, while the positioning plate 3-1d is inserted into the gap of the core material. The spring is compressed, and even if unevenness occurs, the positioning plate 3-1d is always inserted into the gap of the core material under the action of the spring force.

[0041] During the movement of the mobile device, the positioning plate 3-1d is stuck in the core material gap 1-1. The width of the core material gap 1-1 is different. As the foam enters between the positioning plates 3-1d, the two opposing positioning plates 3-1d and the rotating plate 3-1c are stretched apart to adapt to the width of the core material gap, thereby increasing the relative height between them and the core material surface. At this time, under the elastic force of the spring, the bottom edge of the rotating plate can still be pressed against the core material surface.

[0042] In other embodiments of the present invention, the rotating plate 3-1c may not be L-shaped, but may be flat or nearly flat. The lifting rod 3-1h is a rigid rod, and the relative height between the glue-applying box and the core material surface is controlled by an active telescopic device. The active telescopic device keeps the relative height between the glue-applying box and the core material surface constant according to the height change of the core material, thereby keeping the insertion depth of the positioning plate into the core material gap constant, ensuring smooth operation of the glue-applying box 3-1, and thus ensuring uniform injection of foaming adhesive. To keep the height of the glue-applying box constant, a distance sensor can be installed on the glue-applying box to obtain the relative height between the glue-applying box and the core material surface at the distance sensor installation position, and transmit it to the control device of the active telescopic device. The control device controls the lifting and lowering of the glue-applying box. For example, when the core material height is high at a certain position, the distance sensor measures a small relative height between the glue-applying box and the core material surface. At this time, the positioning plate is inserted too deeply into the core material gap, thereby sending a signal to the control device of the active telescopic device. The output shaft of the active telescopic device retracts, thereby pulling up the glue-applying box, thus keeping the relative height between the glue-applying box and the core material surface constant, and ensuring that the positioning plate is not inserted too deeply. Meanwhile, when the positioning plate opens or retracts, the distance sensor and active telescopic device can ensure that the height between the glue box and the core material surface remains constant.

[0043] A baffle 3-1f is provided at the rear end of the plate 3-1a. The baffle 3-1f is mounted on the plate 3-1a via a rotating shaft 3-1e, thereby rotatably connecting the baffle 3-1f to the plate 3-1a. A roller 3-1g is provided at the lower end of the baffle 3-1g, and the rolling direction of the roller 3-1g is consistent with the traveling direction of the glue dispensing box. After the expanding foam is injected into the core material gap 1-1, the roller 3-1g passes over the upper surface of the expanding foam to flatten it, keeping the expanding foam level with the core material surface. To ensure that the roller 3-1g flattens the expanding foam, a torsion spring can be provided on the rotating shaft 3-1e. The torsion spring applies a force to the baffle 3-1f, causing the baffle to rotate in the traveling direction, thereby pressing the roller 3-1g firmly against the upper surface of the expanding foam, ensuring better flatness of the expanding foam.

[0044] The bonding device includes a roller I4-2 rotatably mounted above the support plate 2-1. In this embodiment, two vertical plates II4-1 are mounted on the upper part of the support plate 2-1, and the roller I4-2 is rotatably mounted between the two vertical plates II4-1. A roller III4-4 is rotatably mounted below the support plate 2-1, parallel to the roller I4-2, and the rolling direction of the roller III4-4 is the same as the travel direction. In this embodiment, an elongated hole is provided on the support plate 2-1, and a roller II4-3 parallel to the roller III4-4 and roller I4-2 is mounted inside the elongated hole. Hot melt fabric 4-5 is wound on the roller I4-2, and the hot melt fabric 4-5 is unwound through the roller II4-3 and roller III4-4. The roller II4-3 guides the hot melt fabric 4-5, and the roller III4-4 presses the hot melt fabric onto the foam adhesive in the core material gap 1-1. As the moving device moves forward, it drives the roller III4-4 to roll. The hot melt cloth 4-5 has been pressed against the bottom of the roller III4-4 beforehand. As the roller III4-4 rolls, the hot melt cloth 4-5 is pulled out from the roller I4-2 and then pressed onto the foam through the roller II4-3 and roller III4-4.

[0045] In this embodiment, in order to facilitate pressing the hot melt cloth 4-5 between the roll III 4-4 and the foam adhesive, the angle between the extended surface of the hot melt cloth 4-5 (i.e. the surface where the roll I 4-2, roll II 4-3, and roll III 4-4 are located) and the moving direction of the moving device is less than 90°.

[0046] The heating device includes a hot air blower 5-3, which is fixed to the support plate 2-1. The hot air outlet of the hot air blower 5-3 is aimed at the hot melt fabric 4-5 already covered with expanding foam, for heating the hot melt fabric and releasing the adhesiveness of the hot melt fabric 4-5, thereby fixing the core material and expanding foam on both sides through the hot melt fabric. In this embodiment, a support ring 5-1 is provided on the support plate 2-1, and the hot air blower 5-3 passes through the support ring 5-1 and the support plate 2-1, with its air outlet facing directly below the support plate 2-1; a fastening bolt II 5-2 is threaded onto the support ring 5-1 and abuts against the wall of the hot air blower 5-3, thereby fixing the hot air blower 5-3 to the support plate 2-1.

[0047] An embodiment of the method for using a wind turbine blade core material repair device of the present invention includes the following steps:

[0048] (1) Place the core material repair glue in the glue applicator of the glue applicator and fix the glue applicator on the moving device. At the same time, insert the glue nozzle of the glue applicator into the glue box 3-1.

[0049] (2) Place a roll of hot melt fabric 4-5 on the roll I4-2 of the bonding device;

[0050] (3) Confirm the core material 1 that needs to be repaired, move the repair device to one end of the core material gap, insert the guide wheel 2-4 on the moving device into the core material gap 1-1, insert the positioning plate 3-1d of the glue box into the core material gap 1-1, press one end of the hot melt cloth 4-5 onto the bottom of the roll III 4-4, and align the hot air outlet of the hot air blower 5-3 with the core material gap 1-1.

[0051] (4) Turn on the electric glue applicator 3-5 to apply glue for repair. Fill the core material repair glue into the core material gap 1-1 through the glue applicator box. Move the repair device and guide it through the guide wheel 2-4. The roller 3-1g set on the glue applicator box 3-1 rolls the core material repair glue evenly.

[0052] (5) During the movement of the moving device, the hot melt cloth 4-5 moves and unrolls, covering the already filled core material repair adhesive and the core material on both sides. Then, it is heated by the hot air blower 5-3 to release the adhesiveness of the hot melt cloth 4-5, and to bond the core material repair adhesive and the core material on both sides, preventing the core material 1 from moving again, and at the same time helping the repair adhesive to cure quickly.

[0053] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A wind turbine blade core material repair device, comprising a moving device, characterized in that: The mobile device is equipped with a glue applicator, a bonding device, and a heating device sequentially from front to back along the moving direction. The glue applicator includes a glue applicator and a glue box mounted on the mobile device. The glue applicator's nozzle is inserted into the glue box. A lifting rod is vertically mounted on the glue box, and the lifting rod employs a passive telescopic device. Rotating plates are rotatably mounted on both sides of the glue box. The rotating plates have an L-shaped cross-section, with the bottom edges of the pair of rotating plates extending relative to each other. A positioning plate is provided at the bottom of the rotating plates for insertion into the core material gap. After the positioning plate is inserted into the core material gap, the bottom edge of the rotating plate abuts against the core material surface, limiting the insertion depth of the positioning plate. The positioning plate is located at the end of the bottom edge. When expanding foam is injected into the dispensing box through the dispensing hole, the expanding foam first enters between the rotating plate and the positioning plate. Under the expansion force of the expanding foam, the two positioning plates rotate and approach the two side walls of the core material gap. A baffle is rotatably installed at the rear end of the dispensing box, and a roller with the same rolling direction as the moving direction is installed at the lower end of the baffle. After the expanding foam is injected into the core material gap, the roller passes over the upper surface of the expanding foam to keep the expanding foam and the core material surface horizontal. The bonding device includes a roller I for mounting the hot melt fabric and a roller III for leading out the hot melt fabric and applying the hot melt fabric close to the core material. The heating device includes a hot air blower with the air outlet facing downwards.

2. The wind turbine blade core material repair device according to claim 1, characterized in that: The front end of the mobile device is provided with a guide wheel for locking within the gap of the core material and guiding the mobile device.

3. The wind turbine blade core material repair device according to claim 1, characterized in that: The glue applicator is an electric glue applicator, and a glue cylinder is installed on the electric glue applicator, which contains expanding foam.

4. The wind turbine blade core material repair device according to claim 1, characterized in that: The glue dispensing box includes a top plate with a glue dispensing hole for inserting a glue nozzle, and rotating plates on both sides of the plate.

5. A wind turbine blade core material repair device according to claim 1, characterized in that: The other end of the lifting boom is mounted on the active telescopic device on the moving device.

6. The wind turbine blade core material repair device according to claim 1, characterized in that: The moving device is equipped with a roller II that is parallel to roller III and roller I and is positioned between roller III and roller I to guide the hot melt fabric.

7. A method of using a wind turbine blade core material repair device, characterized in that: The wind turbine blade core material repair device is the wind turbine blade core material repair device as described in any one of claims 1-6, and its usage method includes the following steps: Place the core material repair adhesive in the glue applicator of the glue applicator, fix the glue applicator on the moving device, and insert the glue nozzle of the glue applicator into the glue box at the same time; A roll of hot melt fabric is placed on the spool I of the bonding device; Identify the core material that needs repair, move the repair device to one end of the core material gap, insert the guide wheel on the moving device into the core material gap, insert the positioning plate of the glue box into the core material gap, press one end of the hot melt cloth onto the bottom of the roll III, and align the hot air outlet of the hot air blower with the core material gap. Turn on the electric glue applicator to apply glue for repair. Fill the gaps in the core material with the glue through the glue applicator box. Guide the moving repair device with the guide wheels. The rollers on the glue applicator box flatten the core material repair glue. During the movement of the moving device, the hot melt cloth moves and unrolls, covering the already filled core material repair glue and the core material on both sides. Then, the hot air heater heats it to release the adhesiveness of the hot melt cloth, bonding it to the core material repair glue and the core material on both sides.

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