Blade, Blade Forming Method and Wind Turbine Generator Set

Abstract

The present application relates to a blade, a blade forming method, and a wind turbine generator set. The blade includes a blade body and a lapping section. The blade body includes two or more blade segments arranged in sequence along a first direction. One end of two adjacent blade segments facing each other has step surfaces arranged oppositely. Each step surface includes a plurality of support surfaces and connecting surfaces. The plurality of support surfaces are distributed in sequence along the first direction, and a connecting surface is connected between two adjacent support surfaces. An installation groove is formed between the oppositely arranged step surfaces. The lapping section is arranged in the installation groove and connects the step surfaces of two adjacent blade segments. The lapping section includes a plurality of lapping layers laminated along the wall thickness direction. Both ends of the lapping layer are respectively supported on two support surfaces arranged oppositely in the first direction and are connected to the connecting surface. The blade in the embodiment of the present application can form a staggered lapping method to improve the connection strength between two adjacent blade segments, so as to ensure the connection effect.

Description

Technical Field

[0001] The present application relates to the field of wind power technology, and in particular to a blade, a blade forming method, and a wind turbine generator set. Background Art

[0002] As the power of wind turbines continues to increase, the trend towards larger blades has become increasingly evident. Dividing the original blades into two or more sections to form new integrated product modules with customizable weight and size can significantly reduce transportation difficulty and manufacturing costs.

[0003] Currently, segmented blades are mainly connected by mechanical connection or bonding. Mechanical connection is expensive and increases the weight of the blade, while bonding connection has high requirements on the environment and bonding process. At the same time, the control and detection of bonding quality are also difficult.

[0004] Therefore, there is an urgent need to provide a blade, a blade forming method and a wind turbine generator set. Summary of the Invention

[0005] The embodiments of the present application provide a blade, a blade forming method, and a wind turbine generator set, which can form a staggered overlap method to improve the connection strength of two adjacent blade segments to ensure the connection effect.

[0006] On the one hand, according to an embodiment of the present application, a blade is proposed, including: a blade body, including two or more blade segments arranged in sequence along a first direction, the ends of two adjacent blade segments facing each other have relatively arranged step surfaces, each step surface includes multiple supporting surfaces and connecting surfaces, the multiple supporting surfaces are distributed in sequence along the first direction, a connecting surface is connected between two adjacent supporting surfaces, and an installation groove is formed between the relatively arranged step surfaces; an overlapping section, which is arranged in the installation groove and connects the step surfaces of two adjacent blade segments, the overlapping section includes multiple overlapping layers stacked along the wall thickness direction, and the two ends of the overlapping layer are respectively supported on two supporting surfaces arranged relatively in the first direction and are connected to the connecting surface.

[0007] According to one aspect of an embodiment of the present application, a partial area of the blade segment is provided with a plurality of fabric layers stacked along the wall thickness direction, and the dimensions of each fabric layer are gradually changed along the first direction to form a step surface.

[0008] According to one aspect of an embodiment of the present application, each blade segment has an outer shell and a hollow cavity formed by the outer shell. In the wall thickness direction, the two ends of the mounting groove extend to the inner wall surface and the outer wall surface of the outer shell respectively, and form a first opening and a second opening that are connected. The overlapping section fills the mounting groove layer by layer and closes the first opening and the second opening.

[0009] According to one aspect of the embodiments of the present application, the first opening is disposed on the inner wall surface, the second opening is disposed on the outer wall surface, and the width of the installation groove in the first direction increases layer by layer from the first opening to the second opening.

[0010] According to one aspect of the embodiments of the present application, the overlapping section further includes a lining plate, which is laid on the inner wall surface and closes the first opening to form a bottom surface at the bottom of the installation groove. In the wall thickness direction, the overlapping layers are supported on the bottom surface and the supporting surface layer by layer and close the second opening.

[0011] According to one aspect of the embodiments of the present application, in the wall thickness direction, the installation groove includes a first groove section and a second groove section. One end of the first groove section and the second groove section close to each other are butted. One end of the first groove section away from the second groove section extends towards the inner wall surface of the housing to form the first opening, and one end of the second groove section away from the first groove section forms the second opening towards the outer wall surface of the housing; the width of the first groove section in the first direction increases layer by layer from the end close to the second groove section to the first opening, and the width of the second groove section in the first direction increases layer by layer from the end close to the first groove section to the second opening.

[0012] According to one aspect of the embodiments of the present application, the housing includes a housing body and a main beam embedded in the housing body. A stepped surface is formed on the main beam. The blade further includes a coating layer. Adjacent two blade sections are connected with a coating layer. The coating layer covers the butt joint gap of the adjacent two blade sections and is arranged to cover the overlapping section.

[0013] According to one aspect of the embodiments of the present application, each blade section further includes a web, and the web is disposed in the hollow cavity and connected to the main beam; in the first direction, the webs of two adjacent blade sections are butted, and the blade further includes a first reinforcement unit, which is arranged to extend in the first direction and connect the webs of two adjacent blade sections.

[0014] In another aspect, according to the embodiments of the present application, a method for forming a blade is provided, including the following steps: forming a blade section, laying and fixing a plurality of cloth layers in sequence in a partial area of a blade mold, the ends of each cloth layer are staggered in the first direction to form a stepped surface, the stepped surface includes a plurality of supporting surfaces and connecting surfaces, the plurality of supporting surfaces are distributed in sequence in the first direction, and a connecting surface is connected between two adjacent supporting surfaces, pouring and curing each cloth layer to form a blade section; aligning the blade sections, providing a plurality of blade sections and aligning the stepped surfaces of every two blade sections, an installation groove is formed between the relatively arranged stepped surfaces; splicing the blade sections, laying a plurality of overlapping layers in sequence into the installation groove, the two ends of the overlapping layer are respectively supported on two supporting surfaces arranged relatively in the first direction and are connected to the connecting surface, pouring and curing each overlapping layer to connect every two blade sections to form a blade.

[0015] According to one aspect of the embodiments of the present application, the installation groove has a first opening and a second opening that are connected and communicate with each other. The width of the installation groove in the first direction increases layer by layer from the first opening to the second opening. The steps of sequentially laying a plurality of overlapping layers into the installation groove include: closing the first opening through a lining plate, and sequentially laying a plurality of overlapping layers into the installation groove from the side of the second opening until the second opening is closed.

[0016] According to one aspect of the embodiments of the present application, the installation groove has a first opening and a second opening that are connected and communicate with each other. The installation groove has a first groove section and a second groove section. One end of the first groove section and the second groove section that are close to each other are butted. The width of the first groove section in the first direction increases layer by layer from the end close to the second groove section to the first opening. The width of the second groove section in the first direction increases layer by layer from the end close to the first groove section to the second opening. The steps of splicing the blade segments include: sequentially laying a plurality of overlapping layers into the first groove section from the side of the first opening until the first opening is closed. The two ends of the overlapping layer are respectively supported on two support surfaces that are oppositely arranged in the first direction in the first groove section and are arranged in contact with the connection surface, and each overlapping layer in the first groove section is poured and cured; sequentially laying a plurality of overlapping layers into the second groove section from the side of the second opening until the second opening is closed. The two ends of the overlapping layer are respectively supported on two support surfaces that are oppositely arranged in the first direction in the second groove section and are arranged in contact with the connection surface, and each overlapping layer in the second groove section is poured and cured to connect every two blade segments to form a blade.

[0017] In another aspect, according to the embodiments of the present application, a wind turbine generator is provided, including the blade in the above embodiments, or a blade formed by the blade forming method in the above embodiments.

[0018] The blade provided by the embodiments of the present application includes a plurality of blade segments arranged in sequence along the first direction and an overlapping section connecting two adjacent blade segments. To ensure the connection strength between two adjacent blade segments, a stepped surface is provided at the end of the blade segment. The ends of two adjacent blade segments are butted against each other, so as to form an installation groove between the oppositely arranged stepped surfaces. The overlapping section is arranged in the installation groove and connects the stepped surfaces of the two blade segments to realize the splicing of two adjacent blade segments. Specifically, the stepped surface includes a plurality of support surfaces distributed in sequence along the first direction and a connection surface connecting two adjacent support surfaces. The overlapping section includes a plurality of overlapping layers arranged in a stacked manner. The two ends of each overlapping layer along the first direction are respectively supported on the support surfaces of two relatively arranged blade segments and are arranged in contact with the connection surface. Since the support surfaces are distributed in sequence along the first direction, each overlapping layer can be overlapped in a staggered manner on the support surface, so as to form a staggered overlapping method to improve the connection strength between two adjacent blade segments, and reduce the stress concentration at the joint position between two adjacent blade segments, having good damage tolerance and ensuring the connection effect. Description of the Drawings

[0019] The features, advantages, and technical effects of the exemplary embodiments of the present application will be described below with reference to the accompanying drawings.

[0020] Figure 1 is a schematic structural diagram of a blade segment according to an embodiment of the present application;

[0021] Figure 2 is a cross-sectional view of a blade body according to an embodiment of the present application;

[0022] Figure 3 is a cross-sectional view of a blade according to an embodiment of the present application;

[0023] Figure 4 is a cross-sectional view of a blade body according to another embodiment of the present application;

[0024] Figure 5 is a cross-sectional view of a blade according to another embodiment of the present application;

[0025] Figure 6 is a step diagram of a blade forming method according to an embodiment of the present application;

[0026] Figure 7 is a step diagram of a blade forming method according to another embodiment of the present application;

[0027] Figure 8 is a step diagram of a blade forming method according to still another embodiment of the present application.

[0028] Wherein:

[0029] 1 - blade segment; 11 - cloth layer; 12 - outer shell; 121 - shell body; 122 - main beam; 13 - web; 2 - overlapping segment; 21 - overlapping layer; 22 - lining plate;

[0030] S1 - step surface; S11 - support surface; S12 - connection surface; K - installation groove; K1 - first groove segment; K2 - second groove segment;

[0031] X - first direction; Y - second direction; Z - wall thickness direction.

[0032] In the drawings, the same components are denoted by the same reference numerals. The drawings are not drawn to actual scale. Detailed embodiments

[0033] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In the following detailed description, many specific details are set forth in order to provide a thorough understanding of the present application. However, it will be apparent to those skilled in the art that the present application may be practiced without some of these specific details. The following description of the embodiments is only provided to better understand the present application by showing examples of the present application. In the drawings and the following description, at least some of the well-known structures and techniques are not shown in order to avoid unnecessarily obscuring the present application; and, for clarity, the dimensions of some structures may be exaggerated. In addition, the features, structures, or characteristics described below may be combined in any suitable manner in one or more embodiments.

[0034] The orientation terms used in the following description are all the directions shown in the figures, and do not limit the specific structures of the blades, blade forming methods, and wind turbines of the present application. In the description of the present application, it should also be noted that, unless otherwise clearly specified and limited, the terms "mounted" and "connected" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be directly connected or indirectly connected. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0035] For a better understanding of the present application, the following will be combined with Figures 1 to 8 The blades, blade forming methods, and wind turbines according to the embodiments of the present application are described in detail.

[0036] Please refer to Figures 1 to 3 , an embodiment of the present application provides a blade, which includes a blade body and a lap joint section 2. The blade body includes two or more blade sections 1 arranged in sequence along the first direction X. One end of adjacent two blade sections 1 facing each other has a step surface S1 arranged oppositely. Each step surface S1 includes a plurality of support surfaces S11 and a connecting surface S12. The plurality of support surfaces S11 are distributed in sequence along the first direction X, and a connecting surface S12 is connected between adjacent two support surfaces S11. An installation groove K is formed between the oppositely arranged step surfaces S1. The lap joint section 2 is arranged in the installation groove K and connects the step surfaces S1 of adjacent two blade sections 1. The lap joint section 2 includes a plurality of lap layers 21 stacked along the wall thickness direction Z. The two ends of the lap layer 21 are respectively supported on two support surfaces S11 arranged oppositely in the first direction X and are connected to the connecting surface S12.

[0037] The blade in the embodiment of the present application includes a plurality of blade segments 1 arranged in sequence along the first direction X and a lapping segment 2 connecting two adjacent blade segments 1. To ensure the connection strength between two adjacent blade segments 1, a stepped surface S1 is provided at the end of the blade segment 1. The ends of two adjacent blade segments 1 are butted against each other, so as to form an installation groove K between the oppositely arranged stepped surfaces S1. The lapping segment 2 is arranged in the installation groove K and connects the stepped surfaces S1 of the two blade segments 1 to realize the splicing of two adjacent blade segments 1. Specifically, the stepped surface S1 includes a plurality of support surfaces S11 distributed in sequence along the first direction X and a connection surface S12 connecting two adjacent support surfaces S11. The lapping segment 2 includes a plurality of lapping layers 21 arranged in a stacked manner. The two ends of each lapping layer 21 along the first direction X are respectively supported on the support surfaces S11 of the two oppositely arranged blade segments 1 and are arranged in contact with the connection surface S12. Since the support surfaces S11 are distributed in sequence along the first direction X, each lapping layer 21 can be lapped in a staggered manner on the support surfaces S11, so as to form a staggered lapping method to improve the connection strength between two adjacent blade segments 1, and reduce the stress concentration at the joint position between two adjacent blade segments 1, having good damage tolerance and ensuring the connection effect.

[0038] It can be understood that the blade can be only divided into a root section and a tip section, or can be divided into a plurality of blade segments 1. The weight and size of each blade segment 1 can be adjusted according to the product requirements of the blade to reduce the transportation difficulty and manufacturing cost.

[0039] Among them, after the lapping layers 21 are laid layer by layer, auxiliary materials can be poured into the installation groove K to solidify and form the lapping layers 21 and the blade segments 1 on both sides thereof, so as to realize the connection and fixation of two adjacent blade segments 1. Compared with the existing bonding connection and mechanical connection methods, the embodiment of the present application can, while improving the connection strength between two blade segments 1 in a staggered lapping manner, realize the connection and fixation of two adjacent blade segments 1 through a pouring connection method, reduce the requirements for on-site assembly equipment and technology, and improve economic benefits.

[0040] In order to form the stepped surface S1 at the end of the blade segment 1, in some optional embodiments, a plurality of cloth layers 11 arranged in a stacked manner along the wall thickness direction Z are provided in a partial area of the blade segment 1. The sizes of the cloth layers 11 along the first direction X are gradually changed to form the stepped surface S1. By gradually changing the sizes of the cloth layers 11 along the first direction X, a stepped structure can be formed at the end of the blade segment 1. At the same time, the sizes of the lapping layers 21 along the first direction X can be adjusted according to the sizes of the cloth layers 11 along the first direction X, so that the two ends of each lapping layer 21 are in contact with the connection surface S12, thereby filling the installation groove K to realize the splicing of two adjacent blade segments 1.

[0041] Optionally, along the wall thickness direction Z, the difference in the dimension of two adjacent fabric layers 11 along the first direction X is a fixed value, that is, the dimensions of the fabric layers 11 along the first direction X are distributed in an arithmetic progression, and the stepped surfaces S1 at the ends of two adjacent blade segments 1 can be symmetrically arranged, thereby facilitating the laying of the fabric layers 11 and the overlapping layer 21 more conveniently and improving the reliability of the connection of the blade segments 1.

[0042] Please refer to Figures 1 to 3 , in some optional embodiments, each blade segment 1 has a housing 12 and a hollow cavity formed by enclosing the housing 12. In the wall thickness direction Z, both ends of the mounting groove K extend to the inner wall surface and the outer wall surface of the housing 12 respectively, and a first opening and a second opening that are connected are formed. The overlapping section 2 fills the mounting groove K layer by layer and closes the first opening and the second opening. Among them, both ends of the mounting groove K extending to the inner wall surface and the outer wall surface of the housing 12 respectively means that the ends of the blade segment 1 are both provided with stepped surfaces S1 along the wall thickness direction Z. Compared with the structure where only part of the area is provided with stepped surfaces S1, the connection strength between the blade segment 1 and the overlapping layer 21 can be improved, thereby improving the reliability of the connection of the blade segments 1.

[0043] It can be understood that in some other embodiments, considering the structure of the blade segment 1 and the limitation of the area where the stepped surface S1 is arranged, in the wall thickness direction Z, the mounting groove K can only have one end extending to the inner wall surface or the outer wall surface of the housing 12, that is, only part of the area at the end of the blade segment 1 is provided with a stepped surface S1 along the wall thickness direction Z. However, for the convenience of description, the following still takes the example where the ends of the blade segment 1 are both provided with stepped surfaces S1 along the wall thickness direction Z for illustration.

[0044] In some optional embodiments, the first opening is arranged on the inner wall surface, the second opening is arranged on the outer wall surface, and the width of the mounting groove K in the first direction X increases layer by layer from the first opening to the second opening, that is, in the direction from the inner wall surface to the outer wall surface, the dimensions of the fabric layers 11 in the blade segment 1 along the first direction X decrease layer by layer, thereby forming a V-shaped mounting groove, which is more convenient for the operator to lay the overlapping layer 21 into the mounting groove K layer by layer from the outer wall surface side to realize the connection of two adjacent blade segments 1.

[0045] Since it is difficult to form effective support for the overlapping layer 21 located at the first opening when the mounting groove K extends to the inner wall surface to form the first opening, to solve the above problem, in some optional embodiments, the overlapping section 2 further includes a lining plate 22, which is laid on the inner wall surface and closes the first opening to form a bottom surface at the bottom of the mounting groove K. In the wall thickness direction Z, the overlapping layer 21 is supported on the bottom surface and the supporting surface S11 layer by layer and closes the second opening. By arranging the lining plate 22 on the inner wall surface of the housing 12, the overlapping layer 21 located at the first opening can be supported, and at the same time, the first opening can also be sealed by the lining plate 22 to realize perfusion connection after laying the overlapping layer 21 to ensure the connection of two adjacent blade segments 1.

[0046] Please refer to Figure 4 and Figure 5 In addition to forming the V-shaped mounting groove, in some alternative embodiments, in the wall thickness direction Z, the mounting groove K includes a first groove section K1 and a second groove section K2. One end of the first groove section K1 and the second groove section K2 close to each other are butted against each other. One end of the first groove section K1 far from the second groove section K2 extends towards the inner wall surface of the housing 12 to form a first opening, and one end of the second groove section K2 far from the first groove section K1 forms a second opening towards the outer wall surface of the housing 12. The width of the first groove section K1 in the first direction X increases layer by layer from the end close to the second groove section K2 to the first opening, and the width of the second groove section K2 in the first direction X increases layer by layer from the end close to the first groove section K1 to the second opening. That is, by dividing the mounting groove K into the first groove section K1 and the second groove section K2, a funnel-shaped mounting groove is formed. Under the condition that the dimensional difference in the first direction X between two adjacent cloth layers 11 is a certain value, compared with the V-shaped mounting groove, the funnel-shaped mounting groove effectively reduces the areas of the first opening and the second opening, thereby reducing the influence on the strength of the blade segment 1 itself while ensuring the connection strength between adjacent blade segments 1 and improving the overall reliability of the blade.

[0047] It can be understood that the butt joint of one end of the first groove section K1 and the second groove section K2 close to each other includes two cases. One is that the first groove section K1 and the second groove section K2 are interconnected, that is, the groove bottoms of the first groove section K1 and the second groove section K2 share the same bottom. The other is that the first groove section K1 and the second groove section K2 are not interconnected, that is, the first groove section K1 and the second groove section K2 are separated by the cloth layer 11. The specific setting method can be adjusted according to the actual structure of the blade segment 1, and the present application does not make specific limitations on this.

[0048] Please refer to Figures 1 to 5 In some alternative embodiments, the housing 12 includes a housing body 121 and a main beam 122 embedded in the housing body 121, and a step surface S1 is formed on the main beam 122. Since the main beam 122 of the blade segment 1 is itself formed by laying multiple glass fiber cloth layers 11, by staggering the multiple glass fiber cloths of the main beam 122 during preparation, a step surface S1 can be formed at the end of the blade segment 1. Similarly, when the housing 12 further includes a trailing edge beam embedded in the housing body 121, the step surface S1 can also be formed on the trailing edge beam of the blade segment 1 at the same time, improving the preparation efficiency.

[0049] Meanwhile, since the stepped surface S1 is only formed in a partial area of the outer shell 12, in order to ensure the connection of other areas of the blade segment 1, the blade further includes a coating layer. Adjacent two blade segments 1 are connected with the coating layer, and the coating layer covers the butt joint gap of the adjacent two blade segments 1 and is arranged to cover the overlapping section 2. Wherein, the coating layer can be coated on the outer wall surface of the outer shell 12, and at least coated on the leading edge and trailing edge positions of the outer shell 12, so as to ensure the connection strength of the blade segment 1. Optionally, the coating layer can be provided with multiple layers to realize the multi-layer reinforcement of the blade segment 1.

[0050] To further improve the connection strength of the blade segment 1, in some optional embodiments, each blade segment 1 further includes a web 13, and the web 13 is arranged in the hollow cavity and connected with the main beam 122. In the first direction X, the webs 13 of two adjacent blade segments 1 are butted against each other, and the blade further includes a first reinforcement unit, which extends along the first direction X and connects the webs 13 of two adjacent blade segments 1. Since each blade segment 1 further includes a web 13 arranged in the hollow cavity, in addition to connecting the outer shells 12 of two adjacent blade segments 1, the webs 13 of two adjacent blade segments 1 should also be connected, that is, the butt joint gap of the webs 13 of two adjacent blade segments 1 is connected through the first reinforcement unit to realize the connection of the webs 13.

[0051] Optionally, hand-laid fiberglass can be used to connect and seal two opposite webs 13, and the first reinforcement unit can include a reinforced web and / or a hand-laid reinforced cloth layer. The reinforced web refers to a web made of a core material and a skin arranged in a stacked manner. For example, on both sides of the web 13 along the second direction Y, a reinforced web can be arranged on one side and a hand-laid reinforced cloth layer can be arranged on the other side to complete the connection of the web 13. The second direction Y, the first direction X and the wall thickness direction Z are perpendicular to each other in pairs.

[0052] Please refer to Figure 6 , the embodiment of the present application further provides a blade forming method, including the following steps:

[0053] Form the blade segment 1, sequentially lay and fix a plurality of cloth layers 11 in a partial area of the blade mold, the ends of the cloth layers 11 are staggered along the first direction X to form a stepped surface S1, the stepped surface S1 includes a plurality of support surfaces S11 and a connecting surface S12, the plurality of support surfaces S11 are sequentially distributed along the first direction X, and a connecting surface S12 is connected between two adjacent support surfaces S11, pour and cure each cloth layer 11 to form the blade segment 1;

[0054] Align the blade segments 1, provide a plurality of blade segments 1 and align the stepped surfaces S1 of every two blade segments 1, and an installation groove K is formed between the oppositely arranged stepped surfaces S1;

[0055] Join the blade segments 1, and lay multiple overlapping layers 21 in the installation groove K in sequence. The two ends of the overlapping layer 21 are respectively supported on two support surfaces S11 arranged oppositely in the first direction X and are arranged in contact with the connection surface S12. Infuse and cure each overlapping layer 21 to connect every two blade segments 1 to form a blade.

[0056] Among them, in the step of forming the blade segment 1, part of the area of the blade model can be the main beam 122 and / or the trailing edge beam of the blade segment 1. By arranging the ends of multiple fabric layers 11 of the main beam 122 and / or the trailing edge beam of the blade segment 1 in a staggered manner, and fixing each fabric layer 11 layer by layer with spray adhesive, a stepped surface S1 is formed in the area of the main beam 122 and / or the trailing edge beam of the blade segment 1. After fixing each fabric layer 11, the isolation film and the release cloth can be covered according to the normal process flow, and other auxiliary materials can be laid and the mold can be closed after infusion to form the blade segment 1.

[0057] Optionally, the fabric layer 11 can be set as a fiberglass cloth or a biaxial cloth. The staggered dimension between two adjacent fabric layers 11, that is, the dimension of the support surface S11 in the first direction X, can be set to a certain value. When the fabric layer 11 is set as a fiberglass cloth, the staggered dimension between two adjacent fabric layers 11 can be set to 70 mm to 150 mm. When the fabric layer 11 is set as a biaxial cloth, the staggered dimension between two adjacent fabric layers 11 can be set to 50 mm to 150 mm.

[0058] It can be understood that the dimensions of each fabric layer 11 in the first direction X can be adjusted to form stepped surfaces S1 of different shapes, so as to form a V-shaped installation groove or a funnel-shaped installation groove. The blade forming methods for the V-shaped installation groove and the funnel-shaped installation groove will be described below respectively.

[0059] Please refer to Figure 7 , for the V-shaped installation groove, in the step of forming the blade segment 1, along the direction away from the blade mold, the dimensions of each fabric layer 11 in the first direction X can be gradually reduced, so that in the step of aligning the blade segment 1, the formed installation groove K has a first opening and a second opening that are connected, and the width of the installation groove K in the first direction X increases layer by layer from the first opening to the second opening. In this regard, the step of laying multiple overlapping layers 21 in the installation groove K in sequence includes:

[0060] Close the first opening through the lining plate 22, and lay multiple overlapping layers 21 in the installation groove K in sequence from the second opening side until the second opening is closed.

[0061] For the V-shaped installation groove, since the area of the second opening is larger than that of the first opening, the overlapping layer 21 can be laid layer by layer from the second opening side to the first opening side. To support the overlapping layer 21 at the first opening, a lining plate 22 is pre-set to close the first opening. Therefore, the overlapping layer 21 located at the first opening can be supported by the lining plate 22. At the same time, the lining plate 22 can seal the bottom of the installation groove K. Thus, after laying each overlapping layer 21, the two blade segments 1 can be connected by pouring each overlapping layer 21.

[0062] It can be understood that since only multiple overlapping layers 21 need to be laid into the installation groove K from the second opening side for the V-shaped installation groove, when the blade segment 1 includes a housing 12 and a web 13 connected to the housing 12, before the step of closing the first opening by the lining plate 22, it further includes: docking the webs 13 of every two blade segments 1, providing a first reinforcement unit, and connecting the webs 13 of the two blade segments 1 through the first reinforcement unit. That is, after the webs 13 are spliced, the splicing of the housing 12 is realized to improve the forming efficiency.

[0063] Please refer to Figure 8 , for the funnel-shaped installation groove, in the step of forming the blade segment 1, along the direction away from the blade mold, the dimensions of each cloth layer 11 in the first direction X can be set to gradually increase and then gradually decrease. Thus, in the step of aligning the blade segment 1, the formed installation groove K has a first opening and a second opening that are connected. The installation groove K has a first groove segment K1 and a second groove segment K2. One ends of the first groove segment K1 and the second groove segment K2 close to each other are docked. The width of the first groove segment K1 in the first direction X gradually increases layer by layer from the end close to the second groove segment K2 to the first opening, and the width of the second groove segment K2 in the first direction X gradually increases layer by layer from the end close to the first groove segment K1 to the second opening. In this regard, the step of splicing the blade segments 1 includes:

[0064] Laying multiple overlapping layers 21 into the first groove segment K1 in sequence from the first opening side until the first opening is closed. The two ends of the overlapping layer 21 are respectively supported on two support surfaces S11 arranged oppositely in the first direction X in the first groove segment K1 and are arranged in contact with the connection surface S12, and pouring and curing each overlapping layer 21 in the first groove segment K1;

[0065] Laying multiple overlapping layers 21 into the second groove segment K2 in sequence from the second opening side until the second opening is closed. The two ends of the overlapping layer 21 are respectively supported on two support surfaces S11 arranged oppositely in the first direction X in the second groove segment K2 and are arranged in contact with the connection surface S12, and pouring and curing each overlapping layer 21 in the second groove segment K2 to connect every two blade segments 1 to form a blade.

[0066] For a funnel-shaped installation groove, since there are two groove segments formed, when splicing the blade segment 1, it is necessary to lay the overlapping layers 21 in the first groove segment K1 and the second groove segment K2 respectively, and pour and cure them respectively. It can be understood that before the step of sequentially laying multiple overlapping layers 21 from the first opening side to the first groove segment K1, it also includes sealing one end of the first groove segment K1 away from the first opening through the lining plate 22, so that after laying each overlapping layer 21 in the first groove segment K1, the splicing and curing of the first groove segment K1 can be realized by pouring each overlapping layer 21 in the first groove segment K1. And since the first groove segment K1 has been poured and cured, there is no need to lay the lining plate 22, and multiple overlapping layers 21 can be directly laid in the second groove segment K2 from the second opening side in sequence.

[0067] It can be understood that since the funnel-shaped installation groove needs to lay multiple overlapping layers 21 in the installation groove K on the first opening side and the second opening side respectively, when the blade segment 1 includes the outer shell 12 and the web 13 connected to the outer shell 12, before sequentially laying multiple overlapping layers 21 from the first opening side into the first groove segment K1, it also includes: cutting the web 13 of the blade segment 1; after pouring and curing each overlapping layer 21 in the first groove segment K1, and before sequentially laying multiple overlapping layers 21 from the second opening side into the second groove segment K2, it also includes: repairing the web 13 of the blade segment 1, butting the webs 13 of every two blade segments 1, providing a first reinforcement unit, and connecting the webs 13 of the two blade segments 1 through the first reinforcement unit. By the method of cutting the web 13 first and then repairing the web 13, the influence on the laying layer in the first groove segment K1 can be avoided to ensure the laying and pouring of the funnel-shaped installation groove.

[0068] The embodiment of the present application also provides a wind turbine generator, including the blade in the above embodiment, or the blade formed by the blade forming method in the above embodiment. The wind turbine generator provided by the embodiment of the present application has the technical effects of the technical solutions of the blade and the blade forming method in any of the above embodiments, and the explanations of the same or corresponding structures and terms as those in the above embodiments will not be repeated here.

[0069] Although the present application has been described with reference to the preferred embodiments, various improvements can be made to it and its components can be replaced with equivalents without departing from the scope of the present application. In particular, as long as there is no structural conflict, the technical features mentioned in each embodiment can be combined in any way. The present application is not limited to the specific embodiments disclosed in the text, but includes all technical solutions falling within the scope of the claims.

Claims

1. A blade, characterized in that, Comprising: A blade body, including two or more blade segments (1) arranged in sequence along a first direction, one end of adjacent two of the blade segments (1) facing each other having step surfaces (S1) arranged oppositely, each of the step surfaces (S1) including a plurality of support surfaces (S11) and connecting surfaces (S12), the plurality of support surfaces (S11) being distributed in sequence along the first direction, and the connecting surfaces (S12) being connected between adjacent two of the support surfaces (S11), an installation groove (K) being formed between the oppositely arranged step surfaces (S1); A lapping segment (2), arranged in the installation groove (K) and connecting the step surfaces (S1) of adjacent two of the blade segments (1), the lapping segment (2) including a plurality of lapping layers (21) laminated along the wall thickness direction, two ends of each lapping layer (21) being respectively supported on two of the support surfaces (S11) arranged oppositely in the first direction and being arranged in contact with the connecting surface (S12), and each lapping layer (21) being poured and cured between the blade segments (1) to connect every two of the blade segments (1) to form a blade.

2. The blade according to claim 1, wherein, A part of the blade segment (1) is provided with a plurality of cloth layers (11) laminated along the wall thickness direction, and the sizes of the cloth layers (11) are gradually changed along the first direction to form the step surface (S1).

3. The blade according to claim 1, wherein Each blade segment (1) has a housing (12) and a hollow cavity formed by enclosing of the housing (12). In the wall thickness direction, two ends of the installation groove (K) respectively extend to the inner wall surface and the outer wall surface of the housing (12) and form a connected first opening and a second opening, and the lapping segment (2) fills the installation groove (K) layer by layer and closes the first opening and the second opening.

4. The blade according to claim 3, characterized in that, The first opening is arranged on the inner wall surface, the second opening is arranged on the outer wall surface, and the width of the installation groove (K) in the first direction gradually increases from the first opening to the second opening.

5. The blade according to claim 4, characterized in that, The lapping segment (2) further includes a lining plate (22), which is laid on the inner wall surface and closes the first opening to form a bottom surface located at the bottom of the installation groove (K). In the wall thickness direction, the lapping layers (21) are supported on the bottom surface and the support surfaces layer by layer and close the second opening.

6. The blade according to claim 3, wherein In the wall thickness direction, the installation groove (K) includes a first groove segment (K1) and a second groove segment (K2), one end of the first groove segment (K1) and the second groove segment (K2) close to each other being butted, one end of the first groove segment (K1) far from the second groove segment (K2) extending towards the inner wall surface of the housing to form the first opening, and one end of the second groove segment (K2) far from the first groove segment (K1) forming the second opening towards the outer wall surface of the housing; The width of the first groove segment (K1) in the first direction gradually increases from one end close to the second groove segment (K2) to the first opening, and the width of the second groove segment (K2) in the first direction gradually increases from one end close to the first groove segment (K1) to the second opening.

7. The blade according to claim 3, characterized in that, The outer shell (12) includes a shell body (121) and a main beam (122) embedded in the shell body (121). The stepped surface (S1) is formed on the main beam (122). The blade further includes a coating layer. The coating layer connects adjacent two blade segments (1), and the coating layer covers the butt joint gap between adjacent two blade segments (1) and covers the overlapping segment (2).

8. The blade according to claim 7, characterized in that, Each blade segment (1) further includes a web (13). The web (13) is disposed in the hollow cavity and connected to the main beam (122). In the first direction, the webs (13) of adjacent two blade segments (1) are butted against each other. The blade further includes a first reinforcement unit which extends along the first direction and connects the webs (13) of adjacent two blade segments (1).

9. A blade forming method, characterized in that, It includes the following steps: Forming blade segments, sequentially laying and fixing a plurality of fabric layers (11) in a partial area of a blade mold. The ends of each fabric layer (11) are staggered in the first direction to form a stepped surface (S1). The stepped surface (S1) includes a plurality of support surfaces (S11) and connecting surfaces (S12). The plurality of support surfaces (S11) are sequentially distributed in the first direction, and the connecting surface (S12) is connected between adjacent two support surfaces (S11). Infusing and curing each fabric layer (11) to form a blade segment (1). Aligning blade segments, providing a plurality of blade segments (1) and aligning the stepped surfaces (S1) of every two blade segments (1). An installation groove (K) is formed between the oppositely arranged stepped surfaces (S1). Splicing blade segments, sequentially laying a plurality of overlapping layers (21) into the installation groove (K). The two ends of the overlapping layer (21) are respectively supported on two support surfaces (S11) oppositely arranged in the first direction and are connected to the connecting surface (S12). Infusing and curing each overlapping layer (2) to connect every two blade segments (1) to form a blade.

10. The blade forming method according to claim 9, characterized in that, The installation groove (K) has a first opening and a second opening which are communicated with each other. The width of the installation groove (K) in the first direction increases layer by layer from the first opening to the second opening. The step of sequentially laying a plurality of overlapping layers (21) into the installation groove (K) includes: Closing the first opening through a lining plate (22), and sequentially laying a plurality of overlapping layers (21) into the installation groove (K) from the side of the second opening until the second opening is closed.

11. The blade forming method according to claim 9, characterized in that, The installation groove (K) has a first opening and a second opening which are communicated with each other. The installation groove (K) has a first groove section (K1) and a second groove section (K2). One ends of the first groove section (K1) and the second groove section (K2) close to each other are butted against each other. The width of the first groove section (K1) in the first direction increases layer by layer from the end close to the second groove section (K2) to the first opening. The width of the second groove section (K2) in the first direction increases layer by layer from the end close to the first groove section (K1) to the second opening. The step of splicing the blade segments (1) includes: A plurality of overlapping layers (21) are sequentially laid into the first groove section (K1) from the first opening side until the first opening is closed. Two ends of each overlapping layer (21) are respectively supported on two support surfaces (S11) oppositely arranged in the first direction within the first groove section (K1) and are arranged in contact with the connection surface (S12). Each overlapping layer (21) within the first groove section (K1) is filled and solidified. A plurality of overlapping layers (21) are sequentially laid into the second groove section (K2) from the second opening side until the second opening is closed. Two ends of each overlapping layer (21) are respectively supported on two support surfaces (S11) oppositely arranged in the first direction within the second groove section (K2) and are arranged in contact with the connection surface (S12). Each overlapping layer (21) within the second groove section (K2) is filled and solidified to connect every two blade sections (1) to form a blade.

12. A wind power generating set, characterized in that, It includes a blade according to any one of claims 1 to 8, or a blade formed by the blade forming method according to any one of claims 9 to 11.

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