Wind turbine blade with warning structure and method of manufacturing the same

Abstract

The application provides a wind power blade with a warning structure and a preparation method thereof, and belongs to the field of wind power blades. The blade comprises a blade body, a navigation mark warning area is arranged on the blade body, and a warning mark is embedded in the navigation mark warning area. The warning mark comprises at least one night light layer made of a night light material. The warning function and the structure of the application are integrally cured, the operation is simple and feasible, and the efficiency is high. The overall structure of the blade is excellent, and problems such as a film layer and paint peeling off do not occur. The warning structure has excellent warning effects in the daytime and at night, and does not fail due to electrical faults.

Description

Technical Field

[0001] This invention relates to the field of wind turbine blades, specifically to a wind turbine blade with a warning structure and a method for manufacturing a wind turbine blade. Background Technology

[0002] Wind turbines are devices that convert wind energy into electrical energy. To effectively capture wind energy, wind turbines are typically installed on towers 100 meters or higher. According to my country's standards for tall buildings, and to ensure safe flight operations for civil aviation, buildings exceeding 30 meters in height must be painted with aviation marking paint. Since wind turbine blades are mounted on high towers, they also typically require aviation paint to ensure flight safety. Currently, this mainly involves painting a certain area at the blade tip with alternating white and red warning paint. During the day, the red and white colors provide some warning, but at night, only the aviation lights on the wind turbine's weather support provide illumination. If these aviation lights malfunction and are not promptly rectified, it will pose a threat to flight safety. Summary of the Invention

[0003] The purpose of this invention is to provide a wind turbine blade with a warning structure and its preparation method, which solves the problem that the existing method of applying alternating white and red warning paint to a certain area of ​​the blade tip has poor nighttime warning effect.

[0004] To achieve the above objectives, on the one hand, the present invention provides a wind turbine blade with a warning structure, the blade comprising: a blade body, a navigation beacon warning area provided on the blade body, a warning mark embedded in the navigation beacon warning area, and the warning mark comprising at least one luminescent layer made of luminescent material.

[0005] Preferably, the luminescent layer has two layers: the first luminescent layer is a luminescent film, and the second luminescent layer is a cured layer formed by vacuum infusing a polyurethane modified system onto the first luminescent layer and then curing it. The polyurethane modified system has high brightness and energy storage properties.

[0006] Preferably, the polyurethane modified system comprises: polyurethane resin, luminescent powder, and coupling agent.

[0007] Preferably, the navigational aid warning zone is located at the tip region of the blade body, and the length of the navigational aid warning zone is 7%-15% of the blade body length.

[0008] On the other hand, the present invention also provides a method for manufacturing wind turbine blades, the method comprising:

[0009] Pre-treatment of the blade mold and luminescent film;

[0010] After pretreatment, fiberglass cloth, release cloth and luminous film are laid in sequence on the preset position of the blade mold. The preset position corresponds to the navigation warning area on the wind turbine blade. Other parts are laid in accordance with the normal blade layering and laying method.

[0011] An epoxy resin system is vacuum-injected into a blade mold, and the epoxy resin system is cured to form a wind turbine blade.

[0012] After the wind turbine blades are demolded and post-processed, the fiberglass cloth and demolding cloth on the wind turbine blades in the navigation warning area are peeled off, and at least one new layer of fiberglass cloth and one layer of surface felt are laid in sequence in the navigation warning area.

[0013] The navigation warning area of ​​the wind turbine blades is partially covered and vacuum-sealed using a sealing device, and then a polyurethane modified system is injected into the navigation warning area.

[0014] After the polyurethane-modified system in the navigational aid warning area has cured, the sealing device is removed.

[0015] Preferably, the pretreatment of the blade mold includes cleaning the blade mold and applying a release agent inside the blade mold.

[0016] Preferably, the pretreatment of the luminescent film includes: polishing the luminescent film and punching micropores in the luminescent film.

[0017] Preferably, the method further includes polishing the navigation mark warning area after removing the sealing device.

[0018] Preferably, the polyurethane modified system comprises: polyurethane resin, luminescent powder, and coupling agent.

[0019] Preferably, the new fiberglass cloth is a biaxial fiberglass cloth.

[0020] Through the above technical solution, the present invention has at least the following technical effects:

[0021] 1. The warning function and structure of this invention are integrally solidified and molded, making operation simple, feasible, and highly efficient;

[0022] 2. The blade structure of the present invention is excellent and will not have problems such as the film layer and easy paint peeling.

[0023] 3. The warning structure of the present invention has excellent warning effect both day and night, and the warning effect will not fail due to electrical faults;

[0024] 4. The release fabric fiber tearing and peeling design of the present invention can ensure that the shape is conformal and the thickness is controllable, so that the thickness of the navigation mark warning area is consistent with the actual required thickness of the blade in that area; and it can form a rough surface on the surface of the luminous film, improving the adhesion of the luminous film surface.

[0025] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0026] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings:

[0027] Figure 1 This is a partial schematic diagram of a wind turbine blade provided in one embodiment of the present invention;

[0028] Figure 2 This is a partial schematic diagram of a wind turbine blade provided in an optional embodiment of the present invention.

[0029] Figure 3 This is a flowchart of a method for preparing a wind turbine blade according to one embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of the assembly structure of the blade body and the sealing device provided in one embodiment of the present invention;

[0031] Figure 5 yes Figure 4 Enlarged view of part A in the structure shown.

[0032] Explanation of reference numerals in the attached figures

[0033] 1-Blade body; 2-Navigation warning zone; 3-Luminous layer; 4-New fiberglass cloth; 5-Surface felt; 6-Sealing arc plate; 7-Rubber pad; 8-Mounting groove; 9-Pressure plate; 10-Sealing film; 11-Telescopic tube; 12-Sealing groove; 13-Sealing ring. Detailed Implementation

[0034] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0036] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0037] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0038] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0039] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0040] Example 1

[0041] Figure 1 This is a partial schematic diagram of a wind turbine blade provided in one embodiment of the present invention, as shown below. Figure 1 As shown, an embodiment of the present invention provides a wind turbine blade with a warning structure. The blade includes: a blade body 1, a navigation beacon warning area 2 on the blade body 1, a warning beacon embedded in the navigation beacon warning area 2, and the warning beacon includes at least one luminous layer 3 made of luminous material.

[0042] In this embodiment, the warning structure of the fan blade is made of a luminous layer 3 made of luminous material. The overall structure is excellent and will not have problems such as the film layer and easy paint peeling. Secondly, the warning function and structure of this embodiment are integrally solidified and molded, which is simple and feasible to operate and highly efficient.

[0043] In this embodiment, the second luminous layer of the navigational beacon warning zone 2 can display other colors during the day and emit luminescence at night; therefore, the warning structure has excellent warning effect both day and night and will not fail to provide warning due to electrical faults.

[0044] As a further optimization of this embodiment, the luminous layer 3 is provided with two layers. The first luminous layer 3 is a luminous film, and the second luminous layer 3 is a cured layer formed by vacuum infusing a polyurethane modified system onto the first luminous layer 3 and then curing it. The polyurethane modified system has high brightness and energy storage properties, that is, the second luminous layer 3 is located outside the first luminous layer 3, so that the blade body 1 has a dual night warning structure, which improves the service life of the warning structure. For example, after the second luminous layer 3 fails, the first luminous layer 3 can still continue to store energy under light sources or sunlight.

[0045] As a further optimization of this embodiment, the polyurethane modified system includes: polyurethane resin, luminescent powder and coupling agent, wherein the luminescent powder has a mass content of 1%-20%, preferably 8%-15%, and the coupling agent has a mass content of 1%-5%.

[0046] As a further optimization of this embodiment, the navigational aid warning area 2 is located at the tip region of the blade body 1, and the length of the navigational aid warning area 2 is 7%-15% of the length of the blade body 1. The length of the navigational aid warning area 2, which covers the entire tip region of the blade body 1, is flexibly set according to the actual length of the blade body 1. Figure 1 As shown.

[0047] In this embodiment, the navigational aid warning area 2 can also be set in a local area of ​​the blade body 1, for example, at a distance of approximately 2-5m from the blade tip. The length of the navigational aid warning area 2 can be 7%-15% of the length of the blade body 1, and the width of the navigational aid warning area 2 is 40%-100% of the chordal width of the blade body 1. Navigational aid warning areas 2 can also be set on both the front and rear sidewalls of the blade body, such as... Figure 2 As shown.

[0048] Example 2

[0049] Figure 3 This is a flowchart of a method for manufacturing wind turbine blades according to one embodiment of the present invention, as shown below. Figure 3 As shown in the figure, this embodiment provides a method for manufacturing wind turbine blades, the method comprising:

[0050] Step S101: Pre-treat the blade mold and the luminescent film.

[0051] In this embodiment, the pretreatment of the blade mold includes: cleaning the blade mold and applying a release agent inside the blade mold; first, the blade mold is cleaned to ensure that it remains clean, and after cleaning, a release agent is applied to the blade mold.

[0052] In this embodiment, the pretreatment of the luminous film includes: polishing the luminous film and drilling micropores in the luminous film; firstly, the surface roughness of the luminous film is polished using a 500-1000 mesh fine sandblasting device, so that the surface roughness of the polished luminous film is controlled at Ra10-16; then, a drilling device is used to drill holes in the polished luminous film, drilling round holes with a diameter of 2-5 mm every 50-100 mm; preferably, the drilling device uniformly drills micropores of 2 mm, with a hole spacing of 30 mm * 30 mm; after drilling is completed, the luminous film is cleaned for later use; the micropores allow polyurethane resin to pass through the luminous film, so that the luminous film is firmly fixed inside the molded wind turbine blade.

[0053] The high-brightness energy-storing luminescent film of this embodiment is preferably PET (polyester resin), PVC (polyvinyl chloride) or TPU (thermoplastic polyurethane elastomer).

[0054] Step S102: After completing the pretreatment, fiberglass cloth, release cloth and luminous film are laid in sequence on the preset position of the blade mold, which corresponds to the navigation warning area 2 on the wind turbine blade.

[0055] After the release agent in the blade mold dries (or after applying the release agent and waiting 15-30 minutes), the fiberglass cloth, release cloth, and luminous film are sequentially laid on the preset positions of the blade mold. In addition to the area where the fiberglass cloth, release cloth, and luminous film need to be laid, the blade layup, such as continuous mat, surface mat, and fiber fabric, is laid on this position and other positions of the blade mold. The specific laying process is the existing process of existing blade production and is not described in detail in this embodiment.

[0056] In this embodiment, the fiberglass cloth commonly used is biaxial fabric, such as biaxial 800, biaxial 600, biaxial 300, etc. Preferably, the fiberglass cloth laid at the preset position is a layer of biaxial 600, where biaxial 600 refers to a fiberglass cloth with a surface density of 600 g / m². 2 Biaxial 800 refers to the areal density of the fiberglass cloth being 800 g / m². 2 Biaxial 300 refers to the areal density of the fiberglass cloth being 300 g / m². 2 .

[0057] Step S103: Vacuum inject epoxy resin system into the blade mold, and the epoxy resin system is cured to form a wind turbine blade.

[0058] The process of vacuum-injecting epoxy resin system into the blade mold in this embodiment is the same as the existing blade production process, and the specific injection process is not described in detail in this embodiment.

[0059] Step S104: After the wind turbine blade is demolded and post-processed, the fiberglass cloth and demolding cloth on the wind turbine blade in the navigation warning area 2 are peeled off, and at least one new layer of fiberglass cloth 4 and one layer of surface felt 5 are laid in sequence in the navigation warning area 2.

[0060] Due to the release cloth, the fiberglass cloth and the release cloth can be easily torn off from the blade body 1. After peeling off the fiberglass cloth and the release cloth in the navigation warning area 2 of the wind turbine blade, the first layer of luminous layer 3 in the navigation warning area 2 of the blade body 1 can be exposed. At this time, the release cloth can make the surface of the luminous layer have a certain roughness and good surface adhesion. At this time, there is a groove in the navigation warning area 2. At this time, at least one new layer of fiberglass cloth 4 and one layer of surface felt 5 are laid in the groove in sequence.

[0061] In this embodiment, the new fiberglass cloth 4 is preferably biaxial 300, with two layers of new fiberglass cloth 4 laid in the groove.

[0062] Step S105: Use a sealing device to partially cover and vacuum seal the navigation warning area 2 of the wind turbine blade, and then inject a polyurethane modified system into the navigation warning area 2.

[0063] In this embodiment, the navigation beacon warning area 2 is first partially covered and sealed with a sealing device, and then the navigation beacon warning area 2 is partially vacuumed to create a vacuum environment in the groove area; after the prepared polyurethane modified system is poured into the groove, the entire groove is filled with the polyurethane modified system.

[0064] In this embodiment, the sealing device can be a vacuum bag. When the navigation beacon warning area 2 covers the entire tip area of ​​the blade body 1, a vacuum bag is directly set around the navigation beacon warning area for sealing, and then the vacuum bag is evacuated. When the navigation beacon warning area 2 exists in a local area of ​​the blade body 1, the area is locally sealed using a vacuum bag.

[0065] In this embodiment, the polyurethane modified system includes: polyurethane resin, luminescent powder, and coupling agent; wherein, the polyurethane resin can be Konda WD8085A, and the coupling agent is a silane coupling agent, preferably KH550 or KH560.

[0066] Before injecting the polyurethane modified system, the polyurethane modified system needs to be prepared. The preparation steps of the polyurethane modified system are as follows:

[0067] First, after the blades are demolded and post-treated (including edge trimming, putty shaping, and painting), the fiberglass fabric in the beacon area is removed. 30 kg of Coanda WD8085A is weighed, followed by 15% red luminous powder and 1.5% KH550 coupling agent. The mixture is then mechanically stirred until homogeneous. After the blades are demolded, 35 kg of Coanda curing agent WD8085B is added in proportion and stirred further until homogeneous. The red luminous powder enables the second luminous layer 3 to display color during the day, thus serving as a warning during the day.

[0068] Step S106: After the polyurethane modified system in the navigation warning zone 2 has cured, remove the sealing device.

[0069] In this embodiment, after the groove is filled with the polyurethane modified system, it can be cured at room temperature or heated to about 50°C. The wind turbine blade preparation method of this embodiment can ensure that the thickness of the navigation warning area 2 is consistent with the actual required thickness of the blade in that area, without affecting the structural strength of the blade body 1.

[0070] As a further optimization of this embodiment, the method further includes: after removing the sealing device, polishing and grinding the navigation beacon warning area 2 to keep the surface of the blade body 1 smooth, and ensuring that the thickness of the navigation beacon warning area 2 is consistent with the actual required thickness of the blade in that area. Since the amount of grinding work required when the navigation beacon warning area 2 covers the entire blade tip area of ​​the blade body 1 is greater than the amount of grinding work required when the navigation beacon warning area 2 exists only in a localized area of ​​the blade body 1, the coverage range of the navigation beacon warning area 2 can be selected according to actual needs.

[0071] As a further optimization of this embodiment, when the navigational aid warning area 2 exists in a local area of ​​the blade body 1, after the vacuum bag is evacuated, the vacuum bag can adhere tightly to the other parts of the blade body, and under vacuum, the polyurethane modified system is introduced into the navigational aid warning area. However, this method still has the following problems in actual use: if the vacuum bag is not set properly, wrinkles will form in the groove, and after the polyurethane modified system is injected and cured, the wrinkles in the vacuum bag will make the cured surface uneven and have poor flatness, which will increase the workload of subsequent grinding. In order to improve the flatness of the navigational aid warning area 2 after the local polyurethane modified system is injected and cured, the sealing device is modified in this embodiment.

[0072] Specifically, such as Figure 4 and Figure 5As shown, the sealing device includes a sealing arc plate 6, the shape of which is the same as that of the blade body 1, and can fit on the surface of the blade body 1. A rubber pad 7 is provided along the edge of the inner surface of the sealing arc plate 6 to prevent the sealing arc plate 6 from abrading the blade body 1. A vacuum suction cup can be installed on the sealing arc plate 6 to fix the sealing arc plate 6 on the surface of the blade body 1.

[0073] An installation groove 8 is provided on the inner side of the sealing arc plate 6. A pressure plate 9 is provided in the installation groove 8. The pressure plate 9 is also arc-shaped. The size of the pressure plate 9 is slightly smaller than the size of the groove of the navigation beacon warning area 2, that is, there is a small gap between the pressure plate 9 and the groove. A sealing membrane 10 is also provided between the pressure plate 9 and the installation groove 8. The edge of the sealing membrane 10 is fixed to the side wall of the installation groove 8, or the edge of the sealing membrane 10 is directly fixed to the side wall of the sealing arc plate 6 between the installation groove 8 and the rubber pad 7. A telescopic tube 11 is inserted in the middle of the pressure plate 9. The end of the telescopic tube 11 away from the pressure plate 9 passes through the sealing arc plate 6. The telescopic section of the telescopic tube 11 also passes through the through hole provided in the middle of the sealing membrane 10. A sealing groove 12 is provided on the telescopic section of the telescopic tube 11. A sealing ring 13 is provided at the through hole. The sealing ring 13 is fixed in the sealing groove 12.

[0074] After fixing the sealing arc plate 6 onto the blade body 1, the air pump is connected to the telescopic pipe 11 to evacuate the groove area of ​​the navigation warning area 2. As the air pressure decreases, the sealing film 10 shrinks into the groove, pressing the pressure plate 9 into the groove. The pressure plate 9 can also press the surface felt 5 and the new fiberglass cloth 4 into the groove, preventing the surface felt 5 and the new fiberglass cloth 4 from shifting in the groove, which would result in uneven strength distribution after the blade is formed.

[0075] After a vacuum environment is formed in the groove, the polyurethane modified system is poured into the telescopic tube 11 and then into the groove. As the polyurethane modified system is injected, the pressure plate 9 gradually moves out of the groove. When the polyurethane modified system can no longer be injected, it means that the groove area has been filled with the polyurethane modified system.

[0076] After the polyurethane-modified system in the groove is cured, the surface of the molding in the navigation warning area 2 has a high degree of flatness. Only the edge of the navigation warning area 2 needs to be polished, which reduces the amount of subsequent finishing work for the navigation warning area 2.

[0077] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0078] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A wind turbine blade with a warning structure, characterized in that, The blade includes: a blade body (1), a navigational warning area (2) provided on the blade body (1), a warning mark embedded in the navigational warning area (2), and the warning mark including at least one luminous layer (3) made of luminous material. The luminous layer (3) has two layers. The first luminous layer (3) is a luminous film, and the second luminous layer (3) is a cured layer formed by vacuum infusing a polyurethane modified system onto the first luminous layer (3) and curing it. The polyurethane modified system has high brightness and energy storage properties. The polyurethane modified system includes: polyurethane resin, luminescent powder and coupling agent, wherein the mass content of luminescent powder is 1%-20% and the mass content of coupling agent is 1%-5%.

2. The wind turbine blade with a warning structure according to claim 1, characterized in that, The navigational aid warning area (2) is located on the tip region of the blade body (1), and the length of the navigational aid warning area (2) is 7%-15% of the length of the blade body (1).

3. A method for manufacturing a wind turbine blade, applicable to the wind turbine blade with a warning structure as described in any one of claims 1 or 2, characterized in that, The method includes: Pre-treatment of the blade mold and luminescent film; After pretreatment, fiberglass cloth, release cloth and luminous film are laid in sequence on the preset position of the blade mold, which corresponds to the navigation warning area (2) on the wind turbine blade; An epoxy resin system is vacuum-injected into a blade mold, and the epoxy resin system is cured to form a wind turbine blade. After the wind turbine blades are demolded and post-processed, the fiberglass cloth and demolding cloth on the wind turbine blades in the navigation warning area (2) are peeled off, and at least one new layer of fiberglass cloth (4) and one layer of surface felt (5) are laid in sequence in the navigation warning area (2). The navigation warning area (2) of the wind turbine blade is partially covered and vacuum sealed using a sealing device, and then a polyurethane modified system is injected into the navigation warning area (2). After the polyurethane-modified system in the navigation warning area (2) has cured, the sealing device is removed.

4. The method for manufacturing wind turbine blades according to claim 3, characterized in that, Pretreatment of the blade mold includes cleaning the blade mold and applying a release agent inside the blade mold.

5. The method for manufacturing wind turbine blades according to claim 3, characterized in that, The pretreatment of the luminescent film includes polishing the luminescent film and drilling micropores in the luminescent film.

6. The method for manufacturing wind turbine blades according to claim 3, characterized in that, The method also includes polishing the navigation mark warning area (2) after removing the sealing device.

7. The method for manufacturing wind turbine blades according to claim 3, characterized in that, The polyurethane modified system includes: polyurethane resin, luminescent powder, and coupling agent.

8. The method for manufacturing wind turbine blades according to claim 3, characterized in that, The new fiberglass cloth (4) is a biaxial fiberglass cloth.

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