Sail rotor forming process

Abstract

The invention relates to the technical field of sail rotor manufacturing, and discloses a sail rotor forming process which comprises the following steps: S1, mold manufacturing; s2, a demolding unit is added; s3, winding fibers; s4, curing and demolding; and S5, finish machining. According to the forming process for the sail rotor, the rigidity of the variable-rigidity filling type core mold can reach the preset rigidity by adjusting parameters such as the types, the number or the pressure of the filling units, and when the sail rotor is wound and formed on the forming mold, the forming mold does not generate flexural deformation exceeding a preset range; the wind sail rotor formed through winding is high in precision and quality, the wind sail rotor formed through winding is of an integrated structure, no splicing seam exists in the wind sail rotor, and waterproof treatment does not need to be conducted on the splicing seam; the sail rotor has higher strength and rigidity and can better resist deformation and damage, the overall performance of the sail rotor is improved, the service life of the sail rotor is prolonged, and the reliability of the sail rotor is improved.

Description

Technical Field

[0001] The invention relates to the field of sail rotor manufacturing, and more specifically, to a sail rotor forming process. Background Art

[0002] Sail rotors, as an innovative green ship technology, have received widespread attention and application in the shipping industry in recent years. Sail rotors use wind energy as additional transport capacity and generate thrust through rotation, thereby reducing fuel consumption during ship navigation. When a ship is sailing on a specific route with long-term side winds, the sail rotors can capture and utilize wind energy and convert it into power to drag the ship forward. This technology not only helps to reduce ship operating costs, but also effectively reduces the emission of environmental pollutants.

[0003] The filament winding molding process is a commonly used sail rotor molding process. Existing sail rotors usually have larger size requirements (length not less than 17m, diameter not less than 2.8m), and it is necessary to manufacture sail rotor molding molds of corresponding sizes, and then use the filament winding process to manufacture sail rotors that meet the requirements. However, as the length of the sail rotor molding mold increases, the sail rotor molding mold will undergo flexural deformation beyond the preset range during the winding process, resulting in a decrease in the dimensional accuracy of the sail rotor molding mold, affecting the quality of the wound sail rotor. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects in the prior art and provide a high-precision, integrated sail rotor forming process.

[0005] To achieve the above object, the technical solution of the present invention is to provide a sail rotor forming process, comprising the following steps: S1: mold manufacturing, manufacturing a molding mold, and installing the molding mold on a winding machine, the molding mold includes a variable stiffness filling core mold and a filling unit arranged in the variable stiffness filling core mold to ensure the shape of the variable stiffness filling core mold, the variable stiffness filling core mold includes a winding drum and two heads connected to both ends of the winding drum, and the length of the winding drum is greater than the length of the fiber winding; S2: adding a demoulding unit to cover the outer surface of the winding tube with the demoulding unit; S3: Winding the fiber, winding the fiber impregnated with the resin on the outer layer of the demoulding unit by spiral winding, and winding the fiber to a preset thickness, wherein the winding length of the fiber is greater than the length of the sail rotor; S4: curing and demoulding. After the wound fibers are cured, a semi-finished sail rotor is obtained. The forming mold is removed from the winding machine, and then the forming mold is disassembled to separate the semi-finished sail rotor from the forming mold. S5: Finishing.

[0006] By using the sail rotor forming process described in the present invention, by adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold can reach a preset stiffness. When the sail rotor is wound on the forming mold, the forming mold will not undergo flexural deformation beyond a preset range, and the wound sail rotor has high precision and quality.

[0007] Preferably, the filling unit includes high-pressure gas and an adjustable inner support frame, and the variable stiffness filling core mold is made of fiberglass.

[0008] Preferably, S1 comprises the following steps: S11: manufacturing a glass fiber reinforced plastic flat plate and a head, manufacturing a glass fiber reinforced plastic flat plate and a head semi-finished product through a mold, and then cutting and grinding them to obtain a glass fiber reinforced plastic flat plate and a head; S12: rolling the glass fiber reinforced plastic flat plate and bonding the joints to form a winding tube; S13: installing the adjustable inner support frame, first reducing the size of the adjustable inner support frame, placing the adjustable inner support frame into the winding drum, and then increasing the adjustable inner support frame to a preset size, so that the adjustable inner support frame is closely fitted to the inner wall of the winding drum; S14: Install the end caps and bond the two end caps to the two ends of the winding tube to form a sealed space; S15: Fill the sealed space with an appropriate amount of gas.

[0009] Preferably, the demoulding unit is configured as a polyester film, and in S2, at least one layer of polyester film is wound around the outer surface of the winding tube. Such a design can facilitate demoulding and improve demoulding efficiency.

[0010] Preferably, the demoulding unit includes a demoulding agent and a polyester film. In S2, a proper amount of demoulding agent is first applied to the outer surface of the winding tube, and then at least one layer of polyester film is wound on the outer surface of the winding tube. Such a design is conducive to protecting the variable stiffness filling core mold and enhancing the demoulding effect.

[0011] Preferably, the fibers used for winding in S3 are all carbon fibers. Such a design can ensure the quality of the sail rotor while reducing the weight of the sail rotor for easy transportation.

[0012] Preferably, the fibers used for winding in S3 include carbon fibers and other fibers, and the other fibers include at least one of glass fibers, aramid fibers, and basalt fibers. Such a design is conducive to reducing production costs.

[0013] Preferably, in S4, disassembling the molding die comprises the following steps: S41: releasing the high-pressure gas in the variable stiffness filling core mold; S42: Cut off the ends of the caps; S43: The adjustable inner support frame is reduced in size and taken out from the winding cylinder; S44: The winding tube is pulled inward to deform, so as to separate the winding tube from the semi-finished product of the sail rotor.

[0014] Preferably, in S5, the finishing process includes cutting, grinding and polishing, cutting both ends of the semi-finished sail rotor inward by a preset length, so that the length of the cut semi-finished sail rotor is consistent with the length of the sail rotor, and then grinding and polishing the cut semi-finished sail rotor. Such a design is conducive to improving product quality.

[0015] Preferably, in S5, the surface of the polished sail rotor is subjected to coating treatment. Such a design is conducive to improving the corrosion resistance, aesthetics and service life of the sail rotor.

[0016] The beneficial effects of the present invention are: By using the sail rotor forming process described in the present invention, by adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold can reach a preset stiffness. When the sail rotor is wound on the forming mold, the forming mold will not undergo flexural deformation beyond the preset range. The wound sail rotor has high precision and quality, and the wound sail rotor is an integrated structure without any splicing seams, and no waterproofing treatment is required at the splicing seams, which reduces production difficulty and production cost, shortens production time, and improves production efficiency. Since the sail rotor is a continuous whole, the sail rotor has higher strength and stiffness, can better resist deformation and damage, and improves the overall performance, service life and reliability of the sail rotor. In addition, the integrated sail rotor does not need to be spliced ​​and assembled, and does not need to set up a splicing structure. The overall structure is simple, the requirements for maintenance and overhaul personnel are relatively low, and maintenance and overhaul are more convenient. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the three-dimensional structure of the wind turbine rotor winding device; Figure 2 is a schematic side cutaway view of a sail rotor winding device; Figure 3 yes Figure 1 A magnified view of the structure at center A; Figure 4 It is a three-dimensional structural cross-sectional view of the molding die; Figure 5 is a side cross-sectional schematic diagram of a sail rotor in Embodiment 7; Figure 6 It is a schematic diagram of the three-dimensional structure of the head; Figure 7 make Figure 6 A magnified view of the structure at B in the middle; Figure 8 It is a schematic diagram of the three-dimensional structure of a sail rotor; Fig. 9 is a schematic diagram of the three-dimensional structure of the molding die in Example 11; Fig.10 is a partial front cross-sectional schematic diagram of the molding die in Example 11; Fig.11 is a schematic diagram of the three-dimensional structure of the adjustable inner support frame in Example 11; Fig.12 is a schematic diagram of the three-dimensional structure of the annular support portion in Example 11; Fig.13 is a schematic diagram of the three-dimensional structure of the support unit in Example 11; Fig.14 is a right side cross-sectional schematic diagram of the molding die in Example 11; Fig.15 Fig.10 A magnified view of the structure at center C.

[0018] In the figure: 1. variable stiffness filling core mold; 2. adjustable inner support frame; 3. frame; 4. motor; 5. winding claw; 6. transmission assembly; 7. bracket; 8. immersion tank; 9. combing plate; 10. unwinding assembly; 11. combing hole; 12. guide roller; 13. unwinding roller; 14. fiber roll; 15. winding drum; 16. end cap; 17. two-way gas pipeline; 18. first basalt fiber layer; 19. carbon fiber layer; 20. second basalt fiber layer; 21. cylindrical barrel section; 22. Hemispherical shell segment; 23. main body; 24. bottom edge portion; 25. core cavity; 26. valve; 27. drive joint; 28. annular support portion; 29. ​​axial rod; 30. support unit; 31. arc ring; 32. adjustment plate; 33. first support rod; 34. second support rod; 35. adjustment unit; 36. threaded rod; 37. first nut; 38. second nut; 39. third nut; 40. fourth nut; 41. connecting seat; 42. connecting pipe; 43. sealing ring. DETAILED DESCRIPTION

[0019] The subject matter described herein will now be discussed with reference to example embodiments. It should be understood that the discussion of these embodiments is to enable those skilled in the art to better understand and implement the subject matter described herein. The functions and arrangements of the elements discussed may be changed without departing from the scope of protection of the present specification. Various examples may omit, replace or add various processes or components as needed. In addition, the features described relative to some examples may also be combined in other examples.

[0020] In order to better understand the present invention, Figure 1-Figure 15 A sail rotor forming process of the present invention is described in detail.

[0021] Embodiment 1: like Figure 1-Figure 4 As shown, a sail rotor forming process includes: a sail rotor forming process includes the following steps: S1: mold manufacturing, manufacturing a molding mold, and installing the molding mold on a winding machine, the molding mold includes a variable stiffness filling core mold 1 and a filling unit arranged in the variable stiffness filling core mold 1 to ensure the shape of the variable stiffness filling core mold 1, the variable stiffness filling core mold 1 includes a winding drum 15 and two heads 16 connected to both ends of the winding drum 15, and the length of the winding drum 15 is greater than the length of the fiber winding; S2: Adding a demoulding unit to cover the outer surface of the winding tube 15; S3: Winding the fiber, winding the fiber impregnated with the resin on the outer layer of the demoulding unit by spiral winding, and winding the fiber to a preset thickness, wherein the winding length of the fiber is greater than the length of the sail rotor; S4: curing and demoulding. After the wound fibers are cured, a semi-finished sail rotor is obtained. The forming mold is removed from the winding machine, and then the forming mold is disassembled to separate the semi-finished sail rotor from the forming mold. S5: Finishing.

[0022] It should be noted that the fibers are wound around the molding mold. By adjusting parameters such as the type, quantity or pressure of the filling units, the stiffness of the variable stiffness filling core mold 1 can reach a preset stiffness, ensuring that the variable stiffness filling core mold 1 will not undergo flexural deformation beyond a preset range during the winding process.

[0023] In this embodiment, the winding machine includes a frame 3, a motor 4, a winding claw 5, a transmission assembly 6, a bracket 7, an immersion tank 8, a combing plate 9 and an unwinding assembly 10. The frame 3 and the winding claw 5 are both provided with two, and the two winding claws 5 are respectively rotatably mounted on the corresponding two frames 3, the motor 4 is fixedly mounted on one of the frames 3, and the motor 4 is drivingly connected to one of the winding claws 5, the variable stiffness filling core mold 1 is installed between the two winding claws 5, and the axis of the variable stiffness filling core mold 1 coincides with the axis of the winding claw 5, and the bracket 7 is arranged on the transmission assembly 6. The immersion tank 8 and the combing plate 9 are both installed on the bracket 7, and the combing plate 9 is located on the side of the immersion tank 8 away from the variable stiffness filling core mold 1. The combing plate 9 is provided with a plurality of combing holes 11 to facilitate combing the fibers. Each fiber passes through a combing hole 11 to avoid entanglement of multiple fibers during winding and affect the winding effect. The immersion tank 8 contains resin for impregnation, and the immersion tank 8 is provided with a plurality of guide rollers 12. The guide rollers 12 guide the fibers to ensure that the fibers passing through the combing holes 11 are impregnated with resin before winding. The unwinding assembly 10 is arranged on the side of the transmission assembly 6 away from the variable stiffness filling core mold 1, and the unwinding assembly 10 is provided with an unwinding roller 13 and a tension control system, and a fiber roll 14 is installed on the unwinding roller 13, and the tension control system can control the tension of the fiber during the fiber winding process; When the fiber is wound in S3, the motor 4 drives the winding claw 5 to rotate, thereby driving the variable stiffness filling core mold 1 to rotate, and then the fiber impregnated with resin is wound on the winding drum 15. Under the condition of controlling the tension, the fiber can be evenly wound on the winding drum 15, ensuring the quality and density of the winding, and thus ensuring the quality of the product; During the use of the sail rotor, the stress conditions at different positions are different. According to the different stress conditions, the design is carried out to control the winding thickness of the fiber at different positions of the variable stiffness filling core mold 1, so as to obtain a more stable and reliable sail rotor; like Figure 8 As shown, in S5, the semi-finished sail rotor is cut, ground and polished to obtain a sail rotor with a length of 35m and an outer diameter of 5m, and the thickness of the main part 23 of the sail rotor is 9.4mm, and the bottom edge part 24 of the sail rotor is thickened to 23mm, and the length range of the bottom edge part 24 in the axial direction of the sail rotor is 50-80m.

[0024] By using the sail rotor forming process described in the present invention, by adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold can reach a preset stiffness. When the sail rotor is wound on the forming mold, the forming mold will not undergo flexural deformation beyond the preset range. The wound sail rotor has high precision and quality, and the wound sail rotor is an integrated structure without any splicing seams, and no waterproofing treatment is required at the splicing seams, which reduces production difficulty and production cost, shortens production time, and improves production efficiency. Since the sail rotor is a continuous whole, the sail rotor has higher strength and stiffness, can better resist deformation and damage, and improves the overall performance, service life and reliability of the sail rotor. In addition, the integrated sail rotor does not need to be spliced ​​and assembled, and does not need to set up a splicing structure. The overall structure is simple, the requirements for maintenance and overhaul personnel are relatively low, and maintenance and overhaul are more convenient.

[0025] Embodiment 2: As an optimization of Example 1, Figure 4 As shown, the filling unit includes high-pressure gas and an adjustable inner support frame 2, and the material of the variable stiffness filling core mold 1 is glass fiber reinforced plastic.

[0026] It should be noted that the winding tube 15 and the two heads 16 form a fiberglass airbag structure with a core cavity 255. The high-pressure gas provides sufficient support force to the variable stiffness filling core mold 1 to ensure that the molding mold will not undergo flexural deformation beyond a preset range during the fiber winding process. The adjustable inner support frame 2 can provide support force to the variable stiffness filling core mold 1 while maintaining the shape of the variable stiffness filling core mold 1 to ensure the dimensional accuracy of the variable stiffness filling core mold 1.

[0027] Embodiment 3: As an optimization of Example 2, S1 includes the following steps: S11: manufacturing the FRP flat plate and the end cap 16, manufacturing the FRP flat plate and the end cap 16 semi-finished FRP plate by using a mold, and then cutting and grinding the semi-finished FRP flat plate and the end cap 16 to obtain the FRP flat plate and the end cap 16; S12: rolling the glass fiber reinforced plastic flat plate and bonding the joints to form a winding tube 15; S13: installing the adjustable inner support frame 2, first reducing the size of the adjustable inner support frame 2, placing the adjustable inner support frame 2 into the winding drum 15, and then increasing the adjustable inner support frame 2 to a preset size, so that the adjustable inner support frame 2 is closely fitted to the inner wall of the winding drum 15; S14: Install the end cap 16, and bond the two end caps 16 to the two ends of the winding tube 15 to form a sealed space; S15: Fill the sealed space with an appropriate amount of gas.

[0028] It should be noted that the FRP flat plate has a certain degree of flexibility. In S12, the FRP flat plate is rolled into a cylindrical shape, and then the fiber cloth with resin is glued to the joint, and the two ends of the FRP flat plate are glued together; when the adjustable inner support frame 2 is enlarged to a suitable size in S13, the adjustable inner support frame 2 can provide support for the winding tube 15 and maintain the shape of the winding tube 15. After a proper amount of gas is injected into the variable stiffness filling core mold 1, the high-pressure gas and the adjustable inner support frame 2 jointly maintain the shape and size of the winding tube 15 accurately, thereby improving the quality of the product; The sealed space is the core cavity 255 of the variable stiffness filling core mold 1. In S15, variable stiffness filling core molds 1 of different sizes need to be filled with high-pressure gases of different pressure values ​​in order to provide sufficient supporting force for the variable stiffness filling core mold 1. When using a pressure air pump to inflate the sealed space, the gas pressure in the variable stiffness filling core mold 1 can be clearly seen by observing the display screen of the pressure air pump. When the gas pressure in the sealed space is within the preset pressure range, stop inflating.

[0029] In this embodiment, the fiber cloth with resin is bonded to the inner wall of the winding drum 15. During the bonding process, the joint of the winding drum 15 faces the ground, and workers enter the interior of the winding drum 15 to bond the fiber cloth with resin to the joint, which makes bonding more convenient and has a better bonding effect.

[0030] Embodiment 4: As an optimization of Example 3, the demoulding unit is configured as a polyester film, and in S2 , at least one layer of polyester film is wound around the outer surface of the winding drum 15 .

[0031] It should be noted that before winding the fibers, a winding machine is used to wind a polyester film around the outer surface of the winding drum 15. When winding the fibers, the polyester film serves as an isolation layer to separate the winding drum 15 from the wound fibers for easy demoulding and to prevent the resin-impregnated fibers from sticking to the winding drum 15, which would make the formed sail rotor semi-finished product difficult to demould. After the sail rotor semi-finished product is cured and demoulded, the polyester film is torn off for subsequent finishing. Due to the isolation effect of the polyester film, no resin will remain on the outer surface of the winding drum 15, which is beneficial to the cleaning of the winding drum 15 for easy reuse.

[0032] Embodiment 5: As an optimization of Example 4, the demolding unit includes a demolding agent and a polyester film. In S2, a proper amount of demolding agent is firstly coated on the outer surface of the winding tube 15, and then at least one layer of polyester film is wound on the outer surface of the winding tube 15.

[0033] It should be noted that the release agent can form a protective layer on the surface of the winding tube 15, reducing the friction and impact of the sail rotor semi-finished product on the winding tube 15 during the demolding process, thereby extending the service life of the variable stiffness filling core mold 1, and the release agent can evenly cover the outer surface of the winding tube 15, ensuring that the polyester film can fit tightly during the winding process and is not prone to bubbles or wrinkles, thereby improving the uniformity and consistency of demolding.

[0034] Embodiment 6: As an optimization of Example 5, the fibers used for winding in S3 are all carbon fibers.

[0035] It should be noted that carbon fiber is a high-performance fiber material with extremely high strength and modulus, while being extremely light in weight, and having the characteristics of high temperature resistance, wear resistance, corrosion resistance, and fatigue resistance. By using carbon fiber winding molding, lightweight and high-strength sail rotor semi-finished products can be formed, which can ensure the quality of the produced sail rotors, and reduce the weight of the sail rotors, making it easier to carry and reduce transportation costs.

[0036] Embodiment 7: As an optimization of Example 5, the fibers used for winding in S3 include carbon fibers and other fibers, and the other fibers include at least one of glass fibers, aramid fibers, and basalt fibers.

[0037] It should be noted that glass fiber has the advantages of high strength, non-flammability, corrosion resistance, heat insulation, sound insulation, good electrical insulation, etc., and glass fiber is cheap; aramid fiber has the advantages of light weight (greater than carbon fiber), high strength, high modulus, high temperature resistance, corrosion resistance, good electrical insulation, aging resistance, and long life cycle; basalt fiber is a new type of high-performance inorganic fiber material with the advantages of good stability, good electrical insulation, corrosion resistance, combustion resistance, high temperature resistance, and low temperature resistance; the prices of glass fiber, aramid fiber and basalt fiber are all lower than those of carbon fiber. The sail rotor is made by composite of multiple fibers, which can reduce production costs.

[0038] In this embodiment, if Figure 5 As shown, the sail rotor is designed as a three-layer fiber composite structure, and the fibers used for winding include carbon fiber and basalt fiber. The performance of carbon fiber is excellent, but the oxidation resistance is poor. When it is composited with metal, metal carbonization, carburization and electrochemical corrosion will occur. Therefore, the middle layer is wound with carbon fiber, and the produced sail rotor is light and high-strength. Since the carbon fiber is not in direct contact with the metal, metal carbonization, carburization and electrochemical corrosion will not occur. Basalt fiber has good wear resistance and can withstand both low and high temperatures. The price of basalt fiber is lower than that of carbon fiber. Therefore, the innermost layer is wound with basalt fiber, and the produced sail rotor is not easy to wear and can effectively resist the friction heat generated during the operation of the sail rotor. The outermost layer is wound with basalt fiber, and the produced sail rotor is both high and low temperature resistant, can better adapt to temperature changes, is not easy to be damaged, can effectively increase the service life of the sail rotor, and reduce the production cost of the sail rotor. That is, the sail rotor includes a first basalt fiber layer 18, a carbon fiber layer 19 and a second basalt fiber layer 20 from the inside to the outside.

[0039] Embodiment 8: As an optimization of Example 6 or Example 7, in S4, disassembling the molding die includes the following steps: S41: releasing the high-pressure gas in the variable-rigidity filling core mold 1; S42: Cut off the end caps 16 at both ends; S43: The adjustable inner support frame 2 is reduced in size and taken out from the winding drum 15; S44: The winding drum 15 is pulled inward to deform, so as to separate the winding drum 15 from the semi-finished sail rotor product.

[0040] It should be noted that in S41, the two-way gas pipeline 17 on the head 16 is opened, so that the high-pressure gas in the variable stiffness filling core mold 1 can be released to avoid danger when the head 16 is cut off. By cutting off the head 16, it is convenient for workers to enter the winding tube 15, reduce the adjustable inner support frame 2 and take it out, and cut off the heads 16 at both ends. The winding tube 15 is easier to be pulled inward and deformed, which is beneficial to the separation of the fiberglass cylindrical tube and the sail rotor semi-finished product.

[0041] In this embodiment, if Figure 6 As shown, the end cap 16 includes a cylindrical barrel section 21 and a hemispherical shell section 22, and the bidirectional gas pipeline 17 is installed on the hemispherical shell section 22. The cylindrical barrel section 21 is adapted to the winding barrel 15 and the hemispherical shell section 22. The curvature radius of the hemispherical shell section 22 is equal everywhere, and the force is very uniform. When subjected to the same internal pressure, the wall thickness required by the end cap 16 is the smallest, and the edge stress is relatively low and can be ignored. Therefore, the end cap 16 will not produce a large stress concentration at the edge, and the end cap 16 can effectively disperse and resist the internal pressure, thereby maintaining the stability of the gas pressure; Since the length of the winding tube 15 is greater than the winding length of the fiber, even if the edge of the winding tube 15 or the head 16 is damaged, the winding tube 15 and the head 16 can be reused by simply cutting and grinding the edges of the winding tube 15 and the head 16 until the length of the winding tube 15 is less than the winding length of the fiber, or the hemispherical shell segment 22 of the head 16 is damaged, thereby improving the utilization rate of the winding tube 15 and the head 16, reducing the consumption of the winding tube 15 and the head 16, and reducing the production cost.

[0042] Embodiment 9: As an optimization of Example 8, in S5, the finishing includes cutting, grinding and polishing, and both ends of the sail rotor semi-finished product are cut inward by a preset length so that the length of the cut sail rotor semi-finished product is consistent with the length of the sail rotor, and then the cut sail rotor semi-finished product is ground and polished.

[0043] It should be noted that since the winding length of the fiber is greater than the length of the sail rotor, the length of the sail rotor semi-finished product is greater than the length of the sail rotor. When winding the fibers, the fibers at the edges are prone to defects such as overlapping, crossing or loosening. By cutting the two ends of the sail rotor semi-finished product inward by a certain length, these defective parts can be cut off to ensure that the strength and stability of the final sail rotor are not affected.

[0044] In this embodiment, the winding length of the fiber is 37 m, and both ends of the semi-finished sail rotor need to be cut inward by 1 m each to obtain a 35 m long sail rotor.

[0045] Embodiment 10: As an optimization of Example 9, in S5, the surface of the polished sail rotor is subjected to a coating process.

[0046] It should be noted that the corrosion resistance, aesthetics and service life of the sail rotor can be improved by performing surface coating treatment on the sail rotor as needed.

[0047] Embodiment 11: As an optimization of any one of embodiments 1-10, Figure 4 , Figure 6 , Figure 7 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 , Fig.13 , Fig.14 and Fig.15 As shown, the molding die includes the following structure: two end caps 16 are provided with two-way gas pipelines 17, and the two-way gas pipelines 17 are connected to the core cavity 255, and a valve 26 is provided on the two-way gas pipeline 17. By adjusting the opening and closing of the valve 26, it is possible to control whether to inflate or exhaust, and then adjust the gas pressure in the core cavity 255 to ensure that the gas pressure value in the core cavity 255 is within the preset pressure range (1-10MPa), the variable stiffness filling core mold 1 will not be over-expanded, and no flexural deformation beyond the preset range will occur during the winding process. In addition, the two-way gas pipeline 17 is provided on the end cap 16, which will not affect the winding process; Before installing the variable stiffness filling type core mold 1 on the winding machine, open the valve 26, use the digital pressure pump to inflate the core cavity 255 of the variable stiffness filling type core mold 1 through the two-way gas pipeline 17, and observe the gas pressure value in the core cavity 255 through the display screen of the digital pressure pump until the gas pressure value in the core cavity 25 is within the preset pressure range, stop inflating and close the valve 26; If the gas pressure in the core cavity 25 exceeds the preset pressure range due to over-inflation, the valve 26 can be opened again to release part of the gas in the core cavity 25 until the gas pressure in the core cavity 25 is within the preset pressure range, and then the valve 26 is closed; When the valve 26 is closed, the variable stiffness filling core mold 1 is a closed structure, and the gas in the core cavity 25 cannot be discharged through the two-way gas pipeline 17. The gas pressure value in the core cavity 25 is within the preset pressure range. The high-pressure gas in the core cavity 25 can provide sufficient support force for the variable stiffness filling core mold 1 to prevent the variable stiffness filling core mold 1 from flexural deformation beyond the preset range during the winding process. The adjustable inner support frame 2 can provide support for the variable stiffness filling core mold 1 while allowing the winding tube 15 to maintain a cylindrical shape, thereby ensuring that the size of the wound product is more precise, and the variable stiffness filling core mold 1 will not over-expand due to the excessive gas pressure in the core cavity 25, affecting the dimensional accuracy of the winding tube 15.

[0048] The outer side of the end cap 16 is connected with a driving joint 27, and the driving joint 27 is located at the center of the outer surface of the end cap 16, that is, the axis of the driving joint 27 coincides with the axis of the end cap 16, and the winding claw 5 of the winding machine is drivingly connected to the variable stiffness filling type core mold 1 through the driving joint 27. The winding machine drives the driving joint 27 to rotate, thereby driving the variable stiffness filling type core mold 1 to rotate stably to perform fiber winding; The two-way gas pipeline 17 and the drive joint 27 are both detachably connected to the head 16. A connecting seat 41 is fixedly connected to the center of the outer surface of the head 16. The drive joint 27 is threadedly connected to the connecting seat 41. The head 16 is connected to a connecting pipe 42. The two-way gas pipeline 17 is threadedly connected to the connecting pipe 42, and the connection between the two-way gas pipeline 17 and the connecting pipe 42 is sealed by a sealing ring 43. When demoulding, it is necessary to open the valve 26 to release the high-pressure gas in the core cavity 25, cut off the head 16, and then reduce the distance between the two support units 30 so as to remove the adjustable inner support frame 2, thereby facilitating demoulding. If the hemispherical shell segment 22 is damaged after cutting, the two-way gas pipeline 17 and the drive joint 27 can be disassembled and installed on a new head 16 for reuse. It is not necessary for each head 16 to be equipped with a two-way gas pipeline 17 and a drive joint 27, thereby reducing production costs. The adjustable inner support frame 2 includes a plurality of annular support portions 28 spaced apart along the length direction of the winding tube 15, and an axial rod 29 connected to the annular support portion 28. The length direction of the axial rod 29 is consistent with the length direction of the winding tube 15. A mark is provided on the axial rod 29. The mark is the connection position between the annular support portion 28 and the axial rod 29. The annular support portion 28 is connected to the axial rod 29 by binding. The annular support portion 28 includes two support units 30, and the support unit 30 includes an arc ring 31 that fits the inner wall of the winding drum 15, an adjustment plate 32 connected to the end of the arc ring 31, a first support rod 33 fixedly connected to both ends of the arc ring 31, and a plurality of second support rods 34 fixedly connected to the arc ring 31 and the first support rods 33. The two support units 30 are spaced apart by two adjustment units 35, and the adjustment units 35 are mounted on the adjustment plates 32 corresponding to the two support units 30. The length direction of the second support rod 34 is arranged along the radius direction of the arc ring 31, and the second support rod 34 can better provide radial support for the arc ring 31. Each support unit 30 is provided with two adjustment plates 32, that is, each annular support portion 28 is provided with four adjustment plates 32, wherein the two adjustment plates 32 of one support unit 30 cooperate with the two adjustment plates 32 of another support unit 30, and the adjustment unit 35 adjusts the distance between the two support units 30 by adjusting the distance between the two corresponding adjustment plates 32; To ensure that the winding drum 15 can maintain accurate size, the outer diameter of the annular support portion 28 is consistent with the inner diameter of the winding drum 15. The distance between the two support units 30 is reduced by the adjustment unit 35, which can facilitate the placement of the annular support portion 28 into the core cavity 25. Then, the adjustment unit 35 is adjusted again to increase the distance between the two support units 30 until the two arc rings 31 are both in contact with the inner wall of the winding drum 15, and the two arc rings 31 form a standard annular structure. To ensure that the two arc rings 31 form a standard annular structure, after the two adjustment units 35 are adjusted, it is necessary to ensure that the spacing between the two corresponding first support rods 33 meets the requirements. The spacing between the two first support rods 33 can be measured by the outer measuring claws of the vernier caliper. If it does not meet the requirements, the two adjustment units 35 can be fine-tuned until the spacing between the two first support rods 33 meets the requirements, and at this time, the two first support rods 33 are parallel. The adjusting unit 35 includes a threaded rod 36, a first nut 37, a second nut 38, a third nut 39 and a fourth nut 40. The threaded rod 36 is movably sleeved with the adjusting plate 32. The first nut 37, the second nut 38, the third nut 39 and the fourth nut 40 are all threadedly connected with the threaded rod 36. The first nut 37 and the second nut 38 are respectively attached to the two sides of one of the adjusting plates 32, and the third nut 39 and the fourth nut 40 are respectively attached to the two sides of the other corresponding adjusting plate 32. A threaded rod 36 is movably connected with two adjustment plates 32 corresponding to the two support units 30, and the distance between the two corresponding adjustment plates 32 is adjusted by adjusting the positions of the nuts (the first nut 37, the second nut 38, the third nut 39 and the fourth nut 40), thereby adjusting the distance between the two support units 30; The first nut 37, the second nut 38, the third nut 39 and the fourth nut 40 are arranged in sequence on the threaded rod 36. By adjusting the distance between the second nut 38 and the third nut 39, the distance between the two corresponding adjustment plates 32 can be controlled. Then, the first nut 37 and the fourth nut 40 are tightened. The first nut 37 and the second nut 38 cooperate with the threaded rod 36 to jointly limit the position of one of the adjustment plates 32. The third nut 39 and the fourth nut 40 cooperate with the threaded rod 36 to jointly limit the position of the other corresponding adjustment plate 32, thereby fixing the distance between the two corresponding adjustment plates 32, and then completing the adjustment of the distance between the two support units 30, that is, completing the adjustment of the size of the adjustable inner support frame 2.

[0049] The embodiments of the invention are described above in conjunction with the accompanying drawings, but the present embodiment is not limited to the above-mentioned specific implementation modes, which are merely illustrative and not restrictive. Under the guidance of the present embodiment, ordinary technicians in this field can make many forms without departing from the purpose of the present embodiment and the scope of protection of the claims, all of which are within the protection of the present embodiment.

Claims

1. A sail rotor forming process, characterized in that: The following steps are involved: S1: Mould manufacturing, manufacturing a forming mould, and installing the forming mould on a winding machine, the forming mould comprising a variable stiffness filling core mould (1) and a filling unit arranged in the variable stiffness filling core mould (1) to ensure the shape of the variable stiffness filling core mould (1), the variable stiffness filling core mould (1) comprising a winding cylinder (15) and two sealing heads (16) connected to both ends of the winding cylinder (15), the length of the winding cylinder (15) being greater than the length of the fiber winding; S2: adding a demoulding unit, and covering the outer surface of the winding tube (15) with the demoulding unit; S3: Winding the fiber, winding the fiber impregnated with the resin on the outer layer of the demoulding unit by spiral winding, and winding the fiber to a preset thickness, wherein the winding length of the fiber is greater than the length of the sail rotor; S4: curing and demoulding. After the wound fibers are cured, a semi-finished sail rotor is obtained. The forming mold is removed from the winding machine, and then the forming mold is disassembled to separate the semi-finished sail rotor from the forming mold. S5: Finishing.

2. A sail rotor forming process according to claim 1, characterized in that: The filling unit comprises high-pressure gas and an adjustable inner support frame (2), and the material of the variable-rigidity filling core mold (1) is glass fiber reinforced plastic.

3. A sail rotor forming process according to claim 2, characterized in that: S1 includes the following steps: S11: manufacturing a glass fiber reinforced plastic flat plate and a sealing head (16), using a mold to manufacture a glass fiber reinforced plastic flat plate and a sealing head (16) of a semi-finished glass fiber reinforced plastic plate, and then cutting and grinding the semi-finished glass fiber reinforced plastic flat plate and a sealing head (16) to obtain a glass fiber reinforced plastic flat plate and a sealing head (16); S12: rolling the glass fiber reinforced plastic flat plate and bonding the joints to form a winding tube (15); S13: installing the adjustable inner support frame (2), first reducing the size of the adjustable inner support frame (2), placing the adjustable inner support frame (2) into the winding tube (15), and then increasing the size of the adjustable inner support frame (2) to a preset size, so that the adjustable inner support frame (2) is closely fitted to the inner wall of the winding tube (15); S14: installing the sealing heads (16), and bonding the two sealing heads (16) to the two ends of the winding tube (15) respectively to form a sealed space; S15: Fill the sealed space with an appropriate amount of gas.

4. A sail rotor forming process according to claim 1, characterized in that: The demoulding unit is configured as a polyester film. In S2, at least one layer of polyester film is wound around the outer surface of the winding tube (15).

5. A sail rotor forming process according to claim 1, characterized in that: The demoulding unit comprises a demoulding agent and a polyester film. In S2, a suitable amount of demoulding agent is firstly coated on the outer surface of the winding tube (15), and then at least one layer of polyester film is wound on the outer surface of the winding tube (15).

6. A sail rotor forming process according to claim 1, characterized in that: The fibers used for winding in S3 are all carbon fibers.

7. A sail rotor forming process according to claim 1, characterized in that: The fibers used for winding in S3 include carbon fibers and other fibers, and the other fibers include at least one of glass fibers, aramid fibers, and basalt fibers.

8. A sail rotor forming process according to claim 2, characterized in that: In S4, disassembly of the molding die includes the following steps: S41: releasing the high-pressure gas in the variable-rigidity filling core mold (1); S42: Cut off the end caps (16); S43: The adjustable inner support frame (2) is reduced in size and removed from the winding cylinder (15); S44: The winding tube (15) is pulled inward to deform, so that the winding tube (15) is separated from the semi-finished product of the wind sail rotor.

9. A sail rotor forming process according to claim 1, characterized in that: In S5, the finishing includes cutting, grinding and polishing. Both ends of the sail rotor semi-finished product are cut inward by a preset length so that the length of the cut sail rotor semi-finished product is consistent with the length of the sail rotor, and then the cut sail rotor semi-finished product is ground and polished.

10. A sail rotor forming process according to claim 9, characterized in that: In S5, the polished surface of the sail rotor is subjected to a coating process.

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