Automatic production system for processing enhanced foaming core material for fan blade

Abstract

The invention relates to the field of fan blade auxiliary material production equipment, in particular to an automatic production system for processing a reinforced foaming core material for a fan blade, which comprises a plurality of PET foaming substrate thermocompression bonding subsystems and an FPET Block heat treatment subsystem, batch and continuous production is realized through the plurality of PET foaming substrate thermocompression bonding subsystems to prepare a semi-finished product FPET Block, and the FPET Block heat treatment subsystem is connected with the PET foaming substrate thermocompression bonding subsystems. The semi-finished product FPET Block is subjected to heat treatment through an FPET Block heat treatment subsystem to obtain a finished product standard FPET Block, the finished product standard FPET Block is vertically cut and flattened in the y-axis direction to obtain a PET foaming composite core material base material, and the obtained PET foaming composite core material base material is subjected to slotting, punching, edge cutting and flattening and polishing to obtain the reinforced foaming core material. The high-quality PET foaming composite core material for the fan blade can be produced in batches, and the total production cost of the fan blade is reduced.

Description

Technical Field

[0001] The present application relates to the field of auxiliary material production equipment for fan blades, and in particular to an automated production system for processing reinforced foam core materials for fan blades. Background Art

[0002] The quality of wind turbine blades has an important impact on the safety and power generation efficiency of wind power equipment. It is one of the most basic and cost-intensive components of wind turbines. The core components of wind turbine blades include the main beam, trailing edge beam, web, and shell light. The wind turbine blade shell includes upper and lower skins and a reinforced core material filled between the upper and lower skins. For lightweight considerations, the core material is a hard closed-cell foam polymer material, such as PET foam material, PVC foam material, etc.

[0003] The reinforced core material requires good shear strength, and ordinary PET foam boards cannot meet the requirements. The production method of the reinforced core material is as follows: prepare a PET foam substrate, then use a heating plate to heat the surfaces of the two PET foam substrates that need to be hot-pressed and composited until they are melted, and then hot-press and composite the two PET foam substrates to obtain a double PET foam substrate, heat the surfaces of the double PET foam substrate and another PET foam substrate that need to be hot-pressed and composited until they are melted, and then hot-press and composite the double PET foam substrate and another PET foam substrate to obtain a triple PET foam substrate, repeat the above operation to obtain n+1 stacks of PET foam substrates, i.e., the finished product FPET Block, and then cut and flatten the vertical edges of the obtained FPET Block along the y-axis direction to obtain the reinforced core material, and the obtained reinforced core material is slotted, punched, edge cut and flattened, and polished according to the design requirements of the wind turbine blade to obtain the finished reinforced core material.

[0004] The study found that under the above-mentioned existing production mode of reinforced core materials, the production efficiency of reinforced core materials is relatively low, resulting in a relatively high total production cost of wind turbine blades, which is not conducive to the development of large-megawatt wind power generation products. Summary of the invention

[0005] In order to solve the above technical problems, the present application provides an automated production system for processing reinforced foam core materials for wind turbine blades.

[0006] The present application provides an automated production system for processing reinforced foam core materials for fan blades, which is realized by the following technical solutions: An automated production system for processing reinforced foam core materials for fan blades, comprising a plurality of PET foam substrate hot pressing subsystems and an FPET Block heat treatment subsystem, wherein the plurality of PET foam substrate hot pressing subsystems are used to realize batch and continuous production to obtain semi-finished FPET Blocks, wherein the semi-finished FPET Blocks are heat treated by the FPET Block heat treatment subsystem to obtain finished standard FPET Blocks, wherein the finished standard FPET Blocks are vertically cut and flattened along the y-axis direction to obtain a PET foam composite core material substrate, and the obtained PET foam composite core material substrate is slotted, punched, edge cut, flattened, and polished to obtain a reinforced foam core material for fan blades; The PET foam substrate hot pressing subsystem is marked as n, and the PET foam substrate hot pressing subsystem at the starting end is marked as n=Number.ONE. The PET foam substrate hot pressing subsystem at the starting end hot pressing and molding the PET foam substrate / prepreg tape / PET foam substrate to obtain two stacks of PET foam substrates; the PET foam substrate hot pressing and molding subsystem downstream of the PET foam substrate hot pressing and molding subsystem is marked as Number.TWO, and hot pressing and molding two stacks of PET foam substrates / prepreg tapes / PET foam substrates to obtain three stacks of PET foam substrates. It can be seen that the PET foam substrate hot pressing and molding subsystem is marked as n, and hot pressing and molding n stacks of PET foam substrates / prepreg tapes / PET foam substrates to obtain n+1 stacks of PET foam substrates. When n=Number.ONE, one stack of PET foam substrates is the PET foam substrate; the n+1 stacks of PET foam substrates output by the PET foam substrate hot pressing and molding subsystem at the end are the semi-finished FPET Block, and the obtained semi-finished FPET Block is input into the downstream FPET The finished standard FPET Block can be obtained by heat treatment in the Block heat treatment subsystem; the thickness of the reinforced foam core material for fan blades depends on the vertical cutting method along the y-axis direction, and the length of the reinforced foam core material for fan blades depends on the number of PET foam substrates hot-pressed and composited in the n+1 stacked PET foam substrates.

[0007] This application can mass-produce high-quality PET foam composite core materials for wind turbine blades, reduce the total production cost of wind turbine blades, and thus facilitate the development and breakthrough of large-megawatt wind power generation products.

[0008] Preferably, a single PET foam substrate hot pressing subsystem comprises a conveying belt assembly, a prepreg coil storage roller, a first release paper peeling roller, a first hot pressing roller, a first release paper recycling roller, a laser scanning and heating assembly, a second hot pressing roller, a second release paper recycling roller, a third hot pressing roller, a leveling roller, and a PET foam substrate handling assembly, wherein the prepreg coil storage roller is rolled up with a prepreg coil; the operation process of the PET foam substrate hot pressing subsystem is as follows: after the prepreg coil passes through the first release paper peeling roller, the first release paper is peeled off, the surface of the prepreg stripped of the first release paper is melted by the laser emitted from the laser scanning and heating assembly and then transmitted to the first hot pressing roller, the prepreg stripped of the first release paper is hot-pressed and composited with the PET foam substrate or n stacks of PET foam substrates conveyed by the conveying belt assembly, the prepreg and the PET foam substrate or n stacks of PET foam substrates are hot-pressed and composited, and at the same time, the second release paper is separated at the second hot pressing roller, the second release paper is recovered on the second release paper recycling roller, and then the second hot pressing roller The output PET foam substrate with a hot-pressed prepreg tape on the upper surface or n stacks of PET foam substrates are input to the third hot-pressing roller, and the third hot-pressing roller performs hot-pressing and melting treatment on the upper surface of the prepreg tape to facilitate hot-pressing and compounding of the prepreg tape with another PET foam substrate, and then input to the PET foam substrate handling assembly. At this time, the conveyor belt assembly is stopped, and the PET foam substrate handling assembly clamps and hot-presses another PET foam substrate on the upper surface of the PET foam substrate with a hot-pressed prepreg tape or the upper surface of n stacks of PET foam substrates to form two stacks of PET foam boards or n+1 stacks of PET foam boards, and then the conveyor belt assembly is started, and the obtained two stacks of PET foam boards or n+1 stacks of PET foam boards are input to the leveling roller for hot-pressing and leveling treatment, and the two stacks of PET foam boards or n+1 stacks of PET foam boards that have undergone hot-pressing and leveling treatment are input to the next PET foam substrate hot-pressing and bonding subsystem to produce three stacks of PET foam boards or n+2 stacks of PET foam boards, and the semi-finished FPET Block can be obtained through continuous production of several PET foam substrate hot-pressing and bonding subsystems.

[0009] Preferably, the central axes of the prepreg tape roll taking-up roller and the first release paper recovery roller are located in the same plane and are perpendicular to the horizontal plane; the central axes of the first hot pressure roller and the first release paper stripping roller are located in the same plane and are perpendicular to the horizontal plane, and the first hot pressure roller is located directly above the first release paper stripping roller; and the spacing between the first hot pressure roller and the first release paper stripping roller is equal to 0.98-1.00 times the thickness of the prepreg tape roll.

[0010] Preferably, the laser scanning and heating assembly is arranged between the first release paper peeling roller and the second hot pressing roller, and the second hot pressing roller is located downstream of the first release paper peeling roller; the vertical distance between the second hot pressing roller and the horizontal plane of the conveyor belt in the conveyor belt assembly is equal to 0.98-1.00 times the total thickness of the PET foam substrate and the prepreg tape.

[0011] Preferably, the central axes of the second hot pressing roller and the second release paper recovery roller are located in the same plane which is perpendicular to the horizontal plane; the third hot pressing roller is located downstream of the second hot pressing roller; the vertical distance between the third hot pressing roller and the horizontal plane of the conveyor belt of the conveyor belt assembly is equal to 0.99-1.00 times the total thickness of the PET foam substrate and the prepreg tape; the PET foam substrate handling assembly is arranged between the third hot pressing roller and the leveling roller, and is used to transport the PET foam substrate, and hot-press a PET foam substrate onto n stacks of PET foam substrates with prepreg tapes to form n+1 stacks of PET foam substrates; the height difference between the vertical distance between the leveling roller and the horizontal plane of the conveyor belt of the conveyor belt assembly and the vertical distance between the second hot pressing roller and the horizontal plane of the conveyor belt of the conveyor belt assembly is the height of a single PET foam substrate.

[0012] Preferably, the rotation speed of the second hot pressing roller is equal to the transmission speed of the prepreg coil, and the speed at which the conveyor belt assembly transmits the PET foam substrate is equal to the transmission speed of the prepreg coil, that is, the transmission speed of the prepreg coil, the rotation speed of the second hot pressing roller, and the transmission speed of the PET foam substrate are all 3-8 cm / s.

[0013] Preferably, the first hot pressing roller is a hot steel roller, and the roller surface temperature is 80-98°C; Preferably, the second hot pressing roller is a fluororubber roller, and the roller surface temperature is 105-120°C; Preferably, the third hot pressing roller is a polytetrafluoroethylene composite roller, the polytetrafluoroethylene composite roller comprises a heat-conductive polytetrafluoroethylene outer layer and a steel inner roller, the thermal conductivity of the heat-conductive polytetrafluoroethylene outer layer is 0.5-2.0 W / m·K, and the roller surface temperature of the polytetrafluoroethylene composite roller is 145-180°C; Preferably, the leveling roller is a fluororubber roller, and the roller surface temperature is room temperature.

[0014] Preferably, the laser scanning and heating assembly includes a first screw, a screw drive motor, and a laser emitter moving axially along the first screw. The scanning speed of the laser emitter is 0.2-2.0 m / s, the laser scanning power is 200-500 W, and the surface temperature of the composite prepreg tape after laser scanning is 180-240°C.

[0015] Preferably, the FPET Block heat treatment subsystem includes a semi-finished FPET Block conveyor belt assembly, an oven, and a hot pressing roller group. The oven is arranged on the semi-finished FPET Block conveyor belt assembly, and the semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly is transferred to the oven for heat treatment; the hot pressing roller group is arranged in the oven, specifically, the hot pressing roller group includes a plurality of hot pressing rollers rotatably arranged in the oven, the central axes of all the hot pressing rollers are in the same horizontal plane, and the vertical distance between the roller surface of a single hot pressing roller and the surface of the semi-finished FPET Block conveyor belt in the conveyor belt assembly is equal to 0.998-1.000 times the height of the finished standard FPET Block; the hot pressing rollers in the hot pressing roller group are all fluororubber rollers; the ambient temperature in the oven is set to 80-90°C.

[0016] Preferably, the transmission speed of the semi-finished FPET Block on the conveyor belt assembly is equal to the heat transmission speed of the PET foam substrate in the PET foam substrate hot pressing subsystem or the heat transmission speed of n stacks of PET foam substrates.

[0017] In summary, this application has the following advantages: 1. The present invention can mass-produce high-quality PET foam composite core materials for wind turbine blades, reduce the total production cost of wind turbine blades, and thus facilitate the development and breakthrough of large-megawatt wind power generation products.

[0018] 2. The present invention and the matching prepreg coil can be used to mass-produce high-quality PET foam composite core materials for wind turbine blades and can also improve the mechanical strength and service life of the prepared PET foam composite core materials.

[0019] 3. The present invention can improve the mechanical strength and service life of the prepared PET foam composite core material by optimizing the process parameters, thereby ensuring production efficiency and reducing the total production cost of wind turbine blades. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a simplified diagram of the production process of the automated production system for processing reinforced foam core materials for wind turbine blades in the embodiment.

[0021] Figure 2 This is a diagram showing production details of an automated production system for processing reinforced foam core materials for wind turbine blades in an embodiment.

[0022] Figure 3 Schematic diagram of the structure of the PET foam substrate hot pressing subsystem in the embodiment.

[0023] Figure 4 It is a schematic diagram of the structure of the laser scanning heating component in the PET foam substrate hot pressing subsystem.

[0024] Figure 5 Schematic diagram of the structure of the FPET Block heat treatment subsystem in the embodiment.

[0025] Figure 6 Schematic diagram of the structure of the PET foam substrate handling assembly in the embodiment.

[0026] Figure 7 Schematic diagram of the structure of the clamping jaw assembly of the PET foam substrate handling assembly in the embodiment.

[0027] In the figure, 1, PET foam substrate hot pressing subsystem; 10, PET foam substrate handling assembly; 101, support base; 102, crossbar assembly; 1020, electric push cylinder A; 1021, support slide bar; 1022, sliding screw; 1023, stepping motor; 103, clamping claw assembly; 1031, connecting piece; 1032, main pipe A; 1033, sliding pipe A; 10331, limiting ring; 1034, first cylinder; 1035, platform plate; 1036, second cylinder; 1037, suction plate; 10371, laser transmitter B; 10372, rubber pad; 1038, clamping claw arm; 10381, main pipe B; 10382, sliding tube B; 10383, limiting ring; 10384, third cylinder; 1039, clamp; 10391, rectangular bearing block; 10392, fourth cylinder; 10393, positioning cone; 100, leveling roller; 11, conveyor belt assembly; 12, prepreg roll material storage roller; 13, first release paper peeling roller; 14, first hot pressing roller; 15, first release paper recovery roller; 16, laser scanning and heating assembly; 161, first lead screw; 162, lead screw drive motor; 163, laser transmitter; 17, second hot pressing roller; 18, second release paper recovery roller; 19, third hot pressing roller; 2, FPET Block heat treatment subsystem; 21, semi-finished FPET Block conveyor belt assembly; 22, oven; 23, hot pressing roller group; 24, hot pressing roller. DETAILED DESCRIPTION

[0028] In order to further understand the present invention, preferred embodiments are described below in conjunction with examples and drawings.

[0029] refer to Figure 1-2An automated production system for processing reinforced foam core materials for fan blades includes a plurality of PET foam substrate hot pressing subsystems 1 and an FPET Block heat treatment subsystem 2. A plurality of PET foam substrates and prepreg tapes are continuously hot pressed and compounded through the plurality of PET foam substrate hot pressing subsystems 1 to form semi-finished FPET Blocks, thereby realizing batch and continuous production to obtain semi-finished FPET Blocks. The obtained semi-finished FPET Blocks are heat treated through the FPET Block heat treatment subsystem 2 to obtain finished standard FPET Blocks. The obtained finished standard FPET Blocks are vertically cut along the y-axis direction by a cutting machine to obtain semi-finished reinforced foam core materials for fan blades. The obtained semi-finished reinforced foam core materials for fan blades are edge-grinded to obtain a rough PET foam composite core material substrate. The obtained rough PET foam composite core material substrate is grooved, punched, edge-cut, flattened, and polished to obtain a finished reinforced foam core material for fan blades.

[0030] The prepreg tape is a thermoplastic glass fiber prepreg tape, and the matrix impregnation resin is selected as PET. Preferably, the prepreg tape is a self-made composite prepreg tape, and the PET foam composite core material produced in combination with the composite prepreg tape has relatively good mechanical strength and service life, and also improves the overall production efficiency.

[0031] refer to Figure 1-2, the specific production operation is briefly introduced as follows: the PET foam substrate hot pressing subsystem 1 is marked as n, the PET foam substrate hot pressing subsystem 1 at the starting end is marked as n=Number.ONE, the PET foam substrate hot pressing subsystem 1 at the starting end hot pressing and molding the PET foam substrate / prepreg tape / PET foam substrate to obtain a two-layer PET foam substrate; the PET foam substrate hot pressing and molding subsystem 1 downstream of the PET foam substrate hot pressing and molding subsystem 1 at the starting end is marked as Number.TWO, the PET foam substrate hot pressing and molding subsystem 1 downstream of the PET foam substrate hot pressing and molding subsystem 1 at the starting end hot pressing and molding the two-layer PET foam substrate / prepreg tape / PET foam substrate to obtain a three-layer PET foam substrate. ET foam substrate; the downstream PET foam substrate hot pressing subsystem 1 is marked as Number.THREE, and three stacks of PET foam substrates / prepreg tapes / PET foam substrates are hot pressed to form four stacks of PET foam substrates, ... It can be seen that: the PET foam substrate hot pressing subsystem 1 is marked as n, and n stacks of PET foam substrates / prepreg tapes / PET foam substrates are hot pressed to form n+1 stacks of PET foam substrates; when n=Number.ONE, 1 stack of PET foam substrates is the PET foam substrate; the n+1 stacks of PET foam substrates output by the terminal PET foam substrate hot pressing subsystem 1 are the semi-finished product FPETBlock, and the obtained semi-finished product FPET Block is input into the downstream FPET Block heat treatment subsystem 2 for heat treatment to obtain the finished standard FPET Block.

[0032] The dimensions of the PET foam substrate currently used in the reinforced foam core material for wind turbine blades are 1200 mm in length, 1000 mm in width, and 50 mm in height.

[0033] The size of the reinforced foam core material for fan blades can be flexibly designed. The size of the classic reinforced foam core material for fan blades, that is, the universal reinforced foam core material for fan blades, is 1200mm in length, 1000±10mm in width, and 50mm in height, that is, 20 PET foam substrates and 19 prepreg tapes are continuously hot-pressed and compounded by several PET foam substrate hot pressing subsystems 1, and then heat-treated in the FPETBlock heat treatment subsystem 2 to obtain the finished product FPET Block.

[0034] The thickness of the reinforced foam core material for fan blades depends on the vertical cutting method along the y-axis direction, and the length of the reinforced foam core material for fan blades depends on the number of PET foam substrates that are hot-pressed and composited in the n+1 stacks of PET foam substrates.

[0035] Taking the classic finished product of reinforced foam core material for fan blades as an example, a cutting machine is used to vertically cut along the y-axis direction to obtain a 50mm thick reinforced foam core material for fan blades. The production of the above classic finished product of reinforced foam core material for fan blades requires 19 PET foam substrate hot pressing subsystems 1 and 1 FPET Block heat treatment subsystem 2.

[0036] refer to Figure 3 A single PET foam substrate hot pressing subsystem 1 includes a conveying belt assembly 11, a prepreg coil receiving roller 12, a first release paper peeling roller 13, a first hot pressing roller 14, a first release paper recovery roller 15, a laser scanning and heating assembly 16, a second hot pressing roller 17, a second release paper recovery roller 18, a third hot pressing roller 19, a leveling roller 100, and a PET foam substrate conveying assembly 10. The prepreg coil receiving roller 12 rewinds the prepreg coil.

[0037] The structure of the prepreg tape coil is as follows: the prepreg tape coil includes a plurality of adjacent prepreg tapes, and a first release paper and a second release paper compounded on the upper and lower surfaces of the prepreg tapes. The interval between adjacent prepreg tapes is equal to the interval between adjacent PET foam substrates. On the premise that the transmission speed of the prepreg tape coil is equal to the transmission speed of the PET foam substrate, the continuous hot pressing and compounding operation of the PET foam substrate hot pressing and bonding subsystem 1 can be ensured.

[0038] refer to Figure 3 The laser scanning and heating assembly 16 is disposed between the first release paper peeling roller 13 and the second hot pressing roller 17 through a bracket, and the second hot pressing roller 17 is located downstream of the first release paper peeling roller 13. The vertical distance between the second hot pressing roller 17 and the horizontal plane of the conveyor belt in the conveyor belt assembly 11 is equal to 0.98-1.00 times the total thickness of the PET foam substrate and the prepreg tape. Preferably, the vertical distance between the second hot pressing roller 17 and the horizontal plane of the conveyor belt in the conveyor belt assembly 11 is equal to 1.00 times the total thickness of the PET foam substrate and the prepreg tape.

[0039] refer to Figure 3 , the central axis of the prepreg coiled material receiving roller 12 and the first release paper recovery roller 15 are located in the same plane and are perpendicular to the horizontal plane. And the central axis of the first hot pressing roller 14 and the first release paper peeling roller 13 are located in the same plane and are perpendicular to the horizontal plane. The first hot pressing roller 14 is located downstream of the prepreg coiled material receiving roller 12, and the first hot pressing roller 14 is located directly above the first release paper peeling roller 13. The first hot pressing roller 14 is a hot steel roller, and the roller surface temperature is 80-98°C. The first hot pressing roller 14, i.e., the hot steel roller, preheats the prepreg to facilitate the subsequent hot pressing operation.

[0040] refer to Figure 3The spacing between the first hot pressing roller 14 and the first release paper peeling roller 13 is equal to 0.98-1.00 times the thickness of the prepreg tape coil. Preferably, the spacing between the first hot pressing roller 14 and the first release paper peeling roller 13 is equal to 1 times the thickness of the prepreg tape coil.

[0041] refer to Figure 3 The laser scanning and heating component 16 is located downstream of the first release paper peeling roller 13 and upstream of the second hot pressing roller 17 , that is, the laser scanning and heating component 16 is mounted between the first release paper peeling roller 13 and the second hot pressing roller 17 .

[0042] refer to Figure 3-4 Specifically, the laser scanning and heating assembly 16 rotates and fixes a first lead screw 161 on the bracket, a lead screw driving motor 162 fixedly connected to the bracket for driving the first lead screw 161 to rotate around its own axis, and a laser emitter 163 moving along the axial direction of the first lead screw 161. The line-surface angle between the laser emitted by the laser emitter 163 and the prepreg tape is 45-135°.

[0043] Preferably, the line-plane angle between the laser emitted by the laser emitter 163 and the composite prepreg tape is 90°.

[0044] The scanning speed of the laser emitter 163 is 0.2-2.0 m / s, the laser scanning power is 200-500 W, and the surface temperature of the composite prepreg tape after laser scanning is 180-240° C.

[0045] Preferably, the scanning speed of the laser emitter 163 is 1.0±0.05 m / s, and the scanning speed of the laser emitter 163 is set to 1 m / s during operation. The preferred range of the laser scanning power is 300-400 W, and the laser scanning power of the laser emitter 163 is set to 360 W during operation.

[0046] Based on the scanning speed of the laser emitter 163 being 1 m / s and the laser scanning power being 360 W, the surface temperature of the prepreg tape after laser scanning is 210-215° C., ensuring the bonding stability of the PET foam substrate.

[0047] refer to Figure 3 The second hot pressing roller 17 is located downstream of the laser scanning and heating assembly 16. The central axes of the second hot pressing roller 17 and the second release paper recovery roller 18 are located in the same plane and are perpendicular to the horizontal plane. The second hot pressing roller 17 is a fluororubber roller with a roller surface temperature of 105-120°C.

[0048] refer to Figure 3, the third hot-pressing roller 19 is located downstream of the second hot-pressing roller 17, and the vertical distance between the third hot-pressing roller 19 and the horizontal plane of the conveyor belt of the conveyor belt assembly 11 is equal to 0.99-1.00 times the total thickness of the PET foam substrate and the prepreg tape. Preferably, the vertical distance between the third hot-pressing roller 19 and the horizontal plane of the conveyor belt of the conveyor belt assembly 11 is equal to 1.00 times the total thickness of the PET foam substrate and the prepreg tape.

[0049] refer to Figure 3 The third hot pressing roller 19 is a polytetrafluoroethylene composite roller, which includes a heat-conducting polytetrafluoroethylene outer layer and a steel inner roller. The thermal conductivity of the heat-conducting polytetrafluoroethylene outer layer is 0.5-2.0W / m·K, and the roller surface temperature of the polytetrafluoroethylene composite roller is 145-180°C. The third hot pressing roller 19 can perform a melting and heating treatment on the prepreg tape, so as to facilitate the subsequent hot pressing and compounding of another PET foam substrate at the PET foam substrate conveying assembly 10. When the melting and heating treatment is performed, the material of the polytetrafluoroethylene composite roller does not affect the adhesion and has good peelability.

[0050] refer to Figure 3 The PET foam substrate conveying assembly 10 is disposed between the third hot pressing roller 19 and the leveling roller 100, and is used to convey the PET foam substrate, and hot press a PET foam substrate onto n stacks of PET foam substrates with prepreg tapes to form n+1 stacks of PET foam substrates.

[0051] The PET foam substrate handling assembly 10 can be selected as a commercially available handling robot arm.

[0052] Preferably, a PET foam substrate handling assembly 10 with a specific structure is used, referring to Figure 3 and Figure 6 The PET foam substrate handling assembly 10 includes a support base 101, a crossbar assembly 102 that moves up and down along the support base 101, and a clamping claw assembly 103 that moves left and right along the crossbar assembly 102. The support base 101 is provided with a sliding groove for the crossbar assembly 102 to move up and down along its length direction. The crossbar assembly 102 is fixedly connected to an electric push cylinder A1020, which is fixedly connected to the support base 101. The push rod of the electric push cylinder A1020 is fixedly connected to the crossbar assembly 102. The electric push cylinder A1020 controls the crossbar assembly 102 to move up and down in the sliding groove of the support base 101, and adjusts the clamping height of the clamping claw assembly 103. The clamping claw assembly 103 moves left and right on the crossbar assembly 102, clamps the PET foam substrate, and carries it to a designated position of the conveyor belt of the conveyor belt assembly 11.

[0053] refer to Figure 6-7The crossbar assembly 102 includes two supporting slide bars 1021, and a sliding screw rod 1022 fixedly and rotatably connected to the two supporting slide bars 1021. One end of the sliding screw rod 1022 is rotatably passed through a supporting slide bar 1021 and is located outside the bottom surface of the supporting slide bar 1021. The sliding screw rod 1022 located outside the bottom surface of the supporting slide bar 1021 is fixedly connected to a stepper motor 1023 through a coupling. The stepper motor 1023 drives the sliding screw rod 1022 to rotate around its own axis, so that the clamping jaw assembly 103 moves left and right on the sliding screw rod 1022.

[0054] refer to Figure 6-7 The clamping jaw assembly 103 includes a connecting member 1031 threadedly connected to the sliding screw 1022, a main pipe A1032 is fixedly connected to the lower surface of the connecting member 1031, a sliding pipe A1033 is slidably connected inside the main pipe A1032, a limiting ring 10331 is fixedly connected to the outer wall of the sliding pipe A1033, and the sliding pipe A1033 slides up and down inside the main pipe A1032. Two axisymmetric first cylinders 1034 are fixedly connected to the outer wall of the main pipe A1032. The push rod of the first cylinder 1032 is fixedly connected to the peripheral side of the limiting ring 10331, that is, the first cylinder 1032 can drive the sliding pipe A1033 to slide up and down inside the main pipe A1032. A platform plate 1035 is fixedly connected to the bottom surface of the sliding pipe A1033. Two axisymmetric second cylinders 1036 are fixedly connected to the upper surface of the platform plate 1035. The push rod of the second cylinder 1036 is inserted through and slidably connected to the platform plate 1035 , and the push rod of the second cylinder 1036 is fixedly connected to the suction plate 1037 .

[0055] refer to Figure 6-7 The center of the upper surface of the suction disk 1037 is fixedly connected with a laser emitter 10371. The emitting end of the laser emitter 10371 passes through the suction disk 1037 and is located outside the center of the lower surface of the suction disk 1037. The emitting end of the laser emitter 10371 is exposed to the suction disk 1037 by 1mm, that is, the center of the PET foam substrate is positioned by laser, which improves the accuracy of clamping and improves the overall production efficiency. The bottom surface of the suction disk 1037 is fixedly connected with a rubber pad 10372 with a thickness of 1.2-1.5mm, and the bottom surface of the rubber pad 10372 is fixedly connected with a nano-glue layer. The peripheral side of the platform disk 1035 is detachably and fixedly connected with a plurality of clamping claw arms 1038.

[0056] refer to Figure 6-7The clamping claw arm 1038 includes a main pipe B10381, in which a sliding pipe B10382 is slidably connected. The outer wall of the sliding pipe B10382 is fixedly connected to a limiting ring plate 10383. The outer wall of the main pipe B10381 is fixedly connected to a third cylinder 10384. The push rod of the third cylinder 10384 is fixedly connected to the peripheral side of the limiting ring plate 10383, that is, the third cylinder 10384 can drive the sliding pipe B10382 to slide up and down in the main pipe B10381. One end of the clamping claw arm 1038 is detachable and fixedly connected to the peripheral side of the platform plate 1035, and the other end is detachable and fixedly connected to a clamp 1039, that is, the bottom of the sliding pipe B10382 is detachable and fixedly connected to the clamp 1039.

[0057] refer to Figure 6-7 The clamp 1039 includes a rectangular support block 10391, a fourth cylinder 10392, and a positioning cone 10393. The rectangular support block 10391 is detachable and fixedly connected to the bottom of the sliding tube B10382, and the rectangular support block 10391 is perpendicular to the horizontal plane. The fourth cylinder 10392 is fixedly connected to the outer side of the rectangular support block 10391. The push rod of the fourth cylinder 10392 slides through the rectangular support block 10391 and is located on the inner side of the inner side of the rectangular support block 10391. The positioning cone 10393 is fixedly connected to the push rod surface of the fourth cylinder 10392 that slides through the rectangular support block 10391. The fourth cylinder 10392 pushes the positioning cone 10393 to move in the horizontal direction to clamp the PET foam substrate.

[0058] refer to Figure 6-7 The third cylinder 10384 can drive the sliding tube B10382 to slide up and down in the main tube B10381 to adjust the position of the positioning cone 10393, so that the clamping point of the positioning cone 10393 can be positioned at the side center of the PET foam substrate, thereby improving the overall clamping and carrying stability of the clamping claw arm 1038.

[0059] refer to Figure 6-7 , the specific connection method between the clamping claw arm 1038 and the platform plate 1035 is as follows: the outer wall of the platform plate 1035 is fixedly connected to two annular disc bodies A, and the two annular disc bodies A are coaxially spaced. One end of the main pipe B10381 of the clamping claw arm 1038 is fixedly connected to the annular disc body B, and the annular disc body B is coaxially arranged between the two annular disc bodies A. The two annular disc bodies A and the annular disc body B are penetrated with fixing screws. After adjusting the inclination angle of the clamping claw arm 1038, the fixing screw is screwed with the nut, and the clamping claw arm 1038 can be fixedly connected to the platform plate 1035. In order to adapt to the length of the PET foam substrate, the inclination angle of the clamping claw arm 1038 and the outward sliding distance of the sliding pipe B10382 can be adjusted to meet the processing and production of non-standard PET foam substrates.

[0060] refer to Figure 6-7 , the specific connection method between the clamp 1039 and the sliding tube B10382 on the clamping claw arm 1038 is as follows: the other end of the main tube B10381 of the clamping claw arm 1038 is fixedly connected to two circular disc bodies C, and the two circular disc bodies C are coaxially arranged at intervals. The upper surface of the rectangular parallelepiped bearing block 10391 is fixedly connected to a circular disc body D, and the circular disc body D is coaxially arranged between the two circular disc bodies C. The two circular disc bodies C and the circular disc body D are penetrated with fixing screws. The rectangular parallelepiped bearing block 10391 is adjusted to be perpendicular to the horizontal plane, and the fixing screw is screwed with a nut, so that the clamp 1039 can be detachably and fixedly connected to the clamping claw arm 1038.

[0061] refer to Figure 3 The leveling roller 100 is located downstream of the PET foam substrate conveying assembly 10, and performs hot pressing and leveling treatment on the n+1 stacks of PET foam substrates output by the PET foam substrate conveying assembly 10. The leveling roller 100 is a fluororubber roller, and the roller surface temperature is room temperature. The height difference between the vertical distance between the leveling roller 100 and the horizontal plane of the conveyor belt assembly 11 and the vertical distance between the second hot pressing roller 17 and the horizontal plane of the conveyor belt assembly 11 is the height of a single PET foam substrate, which can ensure that a single PET foam substrate hot pressing and bonding subsystem can hot press and bond a piece of PET foam substrate.

[0062] refer to Figure 1-2The operation process of the PET foam substrate hot pressing subsystem 1 is as follows: after the prepreg coil passes through the first release paper peeling roller 13, the first release paper is peeled off, and the surface of the prepreg stripped of the first release paper is melted by the laser emitted from the laser scanning and heating component 16 and then transmitted to the first hot pressing roller 14, the prepreg stripped of the first release paper is hot pressed and compounded with the PET foam substrate or n stacks of PET foam substrates conveyed by the conveying belt component 11, the prepreg and the PET foam substrate or n stacks of PET foam substrates are hot pressed and compounded, and the second release paper is separated from the second hot pressing roller 17, and the second release paper is recovered on the second release paper recovery roller 18, and then the PET foam substrate or n stacks of PET foam substrates of the hot pressed prepreg outputted from the second hot pressing roller 17 are input to the third hot pressing roller 19, and the third hot pressing roller 19 performs hot pressing and melting treatment on the upper surface of the prepreg, so as to facilitate the prepreg The impregnated tape is hot-pressed and compounded with another PET foam substrate, and then input into the PET foam substrate handling assembly 10. At this time, the conveyor belt assembly 11 stops, and the PET foam substrate handling assembly 10 clamps another PET foam substrate and hot-presses it on the upper surface of the PET foam substrate of the hot-pressed prepreg tape or the upper surface of n stacks of PET foam substrates to form two stacks of PET foam boards or n+1 stacks of PET foam boards, and then the conveyor belt assembly 11 is started, and the obtained two stacks of PET foam boards or n+1 stacks of PET foam boards are input into the leveling roller 100 for hot-pressing and leveling treatment, and the two stacks of PET foam boards or n+1 stacks of PET foam boards that have been hot-pressed and leveled are input into the next PET foam substrate hot-pressing subsystem 1 to produce three stacks of PET foam boards or n+2 stacks of PET foam boards, and the semi-finished FPET Block can be obtained through continuous production of several PET foam substrate hot-pressing subsystems 1.

[0063] In order to improve production efficiency, a limited position frame area is set at the starting end of the conveyor belt of the PET foam substrate hot pressing subsystem 1 at the starting end. The limited position frame area at the starting end of the conveyor belt needs to load the PET foam substrate, and there are two ways to load the PET foam substrate: the first way to load the PET foam substrate is to carry it with the PET foam substrate handling component 10, and the second way to load the foam substrate is to manually carry the PET foam substrate.

[0064] The PET foam substrate hot pressing subsystem 1 except the PET foam substrate hot pressing subsystem 1 as the starting end, the starting end of the conveyor belt on the conveyor belt assembly 11 is divided into an n+1 stack of PET foam boards quality inspection area, and the operator will perform appearance inspection on the n+1 stack of PET foam boards to judge the quality of the n+1 stack of PET foam boards.

[0065] refer to Figure 4The FPET Block heat treatment subsystem 2 includes a semi-finished FPET Block conveyor belt assembly 21, an oven 22, and a hot pressing roller group 23. The oven 22 is arranged on the semi-finished FPET Block conveyor belt assembly 21. The semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly 21 is transferred to the oven 22 for heat treatment. The hot pressing roller group 23 is rotatably connected to the oven 22. Specifically, the hot pressing roller group 23 includes a plurality of hot pressing rollers 24 rotatably connected to the oven 22. The central axes of all the hot pressing rollers 24 are in the same horizontal plane. The vertical distance between the roller surface of a single hot pressing roller 24 and the conveyor belt surface in the semi-finished FPET Block conveyor belt assembly 21 is equal to 0.998-1.000 times the height of the finished standard FPET Block. Preferably, the vertical distance between the roller surface of a single hot pressing roller 24 and the conveyor belt surface in the semi-finished FPET Block conveyor belt assembly 21 is equal to 1 times the height of the finished standard FPET Block.

[0066] The hot pressing rollers 24 in the hot pressing roller group 23 are all fluororubber rollers, and the roller surface temperature of the hot pressing rollers 24 is equal to the temperature in the oven 22. The ambient temperature in the oven 22 is set to 80-90°C.

[0067] The length of the oven 22 is controlled to be 4-6m. Preferably, the length of the oven 22 is controlled to be 5m. The transmission speed of the semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly 21 is equal to the transmission speed of the PET foam substrate heat in the PET foam substrate hot pressing subsystem 1 or the transmission speed of the n-stack PET foam substrate heat.

[0068] The semi-finished FPET Block that has been heat treated by the FPET Block heat treatment subsystem 2 can eliminate internal stress, improve the mechanical properties and impact toughness of the finished standard FPET Block, facilitate vertical cutting along the y-axis direction in subsequent work sections, improve the yield rate of the vertical cutting section along the y-axis direction, reduce the overall production cost of wind turbine blades, and benefit the development and breakthrough of large-megawatt wind power generation products.

Claims

1. An automated production system for processing reinforced foam core materials for fan blades, characterized in that: The method comprises a plurality of PET foam substrate hot pressing subsystems (1) and an FPET Block heat treatment subsystem (2), wherein the plurality of PET foam substrate hot pressing subsystems (1) are used to realize batch and continuous production to obtain semi-finished FPET Blocks, wherein the semi-finished FPET Blocks are heat treated by the FPET Block heat treatment subsystem (2) to obtain finished standard FPET Blocks, wherein the finished standard FPET Blocks are vertically cut and trimmed along the y-axis direction to obtain a PET foam composite core material substrate, and the obtained PET foam composite core material substrate is grooved, punched, edge cut, trimmed, and polished to obtain a reinforced foam core material for fan blades; The PET foam substrate hot pressing and sealing subsystem (1) is marked as n. The PET foam substrate hot pressing and sealing subsystem (1) at the starting end is marked as n=Number.ONE. The PET foam substrate hot pressing and sealing subsystem (1) at the starting end hot pressing and sealing subsystem (1) hot presses the PET foam substrate / prepreg tape / PET foam substrate to obtain a double-layer PET foam substrate. The PET foam substrate hot pressing and sealing subsystem (1) downstream of the PET foam substrate hot pressing and sealing subsystem (1) at the starting end is marked as Number.TWO. The foam substrate / prepreg tape / PET foam substrate are heat-pressed to form a three-ply PET foam substrate. It can be seen that: the PET foam substrate heat-pressing subsystem (1) is marked as n, and n stacks of PET foam substrates / prepreg tapes / PET foam substrates are heat-pressed to form n+1 stacks of PET foam substrates. When n=Number.ONE, one stack of PET foam substrates is the PET foam substrate; the n+1 stacks of PET foam substrates output by the terminal PET foam substrate heat-pressing subsystem (1) are the semi-finished FPET Block, and the obtained semi-finished FPET Block is input into the downstream FPET Block heat treatment subsystem (2) for heat treatment to obtain the finished standard FPET Block; the thickness of the reinforced foam core material for fan blades depends on the vertical cutting method along the y-axis direction, and the length of the reinforced foam core material for fan blades depends on the number of PET foam substrates heat-pressed and superimposed in the n+1 stacks of PET foam substrates.

2. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 1, characterized in that: The single PET foam substrate hot pressing subsystem (1) comprises a conveying belt assembly (11), a prepreg coil storage roller (12), a first release paper peeling roller (13), a first hot pressing roller (14), a first release paper recovery roller (15), a laser scanning heating assembly (16), a second hot pressing roller (17), a second release paper recovery roller (18), a third hot pressing roller (19), a leveling roller (100), and a PET foam substrate conveying assembly (10), wherein the prepreg coil storage roller (12) is used to reel in the prepreg coil; the PET foam substrate hot pressing subsystem (1) The operation process is as follows: after the prepreg tape roll passes through the first release paper peeling roller (13), the first release paper is peeled off, the surface of the prepreg tape from which the first release paper is peeled off is melted by the laser emitted from the laser scanning and heating component (16) and then transmitted to the first hot pressing roller (14), the prepreg tape from which the first release paper is peeled off is hot-pressed and laminated with the PET foam substrate or n stacks of PET foam substrates transported by the conveyor belt component (11), the prepreg tape and the PET foam substrate or n stacks of PET foam substrates are hot-pressed and laminated, and at the same time, the second release paper is separated by the second hot pressing roller (17), and the second release paper is recovered in the second release The paper recycling roller (18) is then outputted from the second hot pressing roller (17) and the PET foam substrate or n stacks of PET foam substrates with the prepreg tape on the upper surface are inputted into the third hot pressing roller (19). The third hot pressing roller (19) performs hot pressing and melting treatment on the upper surface of the prepreg tape to facilitate hot pressing and compounding of the prepreg tape with another PET foam substrate. The prepreg tape is then inputted into the PET foam substrate conveying assembly (10). At this time, the conveying belt assembly (11) is stopped, and the PET foam substrate conveying assembly (10) clamps and hot presses another PET foam substrate onto the PET foam substrate or n stacks of PET foam substrates with the prepreg tape on the upper surface. A double stack of PET foam boards or n+1 stacks of PET foam boards are formed on the upper surface of the ET foam substrate, and then the conveyor belt assembly (11) is turned on, and the obtained double stack of PET foam boards or n+1 stacks of PET foam boards are input into the leveling roller (100) for hot pressing and leveling treatment, and the double stack of PET foam boards or n+1 stacks of PET foam boards after hot pressing and leveling treatment are input into the next PET foam substrate hot pressing and leveling subsystem (1) to produce a triple stack of PET foam boards or n+2 stacks of PET foam boards, and after continuous production of several PET foam substrate hot pressing and leveling subsystems (1), a semi-finished product FPET Block can be obtained.

3. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The central axes of the prepreg tape coil storage roller (12) and the first release paper recovery roller (15) are located in the same plane and are perpendicular to the horizontal plane; the central axes of the first hot pressing roller (14) and the first release paper peeling roller (13) are located in the same plane and are perpendicular to the horizontal plane, and the first hot pressing roller (14) is located directly above the first release paper peeling roller (13); and the spacing between the first hot pressing roller (14) and the first release paper peeling roller (13) is equal to 0.98-1.00 times the thickness of the prepreg tape coil.

4. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The laser scanning and heating component (16) is arranged between the first release paper peeling roller (13) and the second hot pressing roller (17), and the second hot pressing roller (17) is located downstream of the first release paper peeling roller (13); the vertical distance between the second hot pressing roller (17) and the horizontal plane of the conveyor belt in the conveyor belt component (11) is equal to 0.98-1.00 times the total thickness of the PET foam substrate and the prepreg tape.

5. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The central axes of the second hot pressing roller (17) and the second release paper recovery roller (18) are located in the same plane and are perpendicular to the horizontal plane; the third hot pressing roller (19) is located downstream of the second hot pressing roller (17); the vertical distance between the third hot pressing roller (19) and the horizontal plane of the conveyor belt of the conveyor belt assembly (11) is equal to 0.99-1.00 times the total thickness of the PET foam substrate and the prepreg tape; the PET foam substrate conveying assembly (10) is arranged between the third hot pressing roller (19) and the leveling roller (100) and is used to convey the PET foam substrate and hot-press a PET foam substrate onto n stacks of PET foam substrates with prepreg tapes to form n+1 stacks of PET foam substrates; the height difference between the vertical distance between the leveling roller (100) and the horizontal plane of the conveyor belt of the conveyor belt assembly (11) and the vertical distance between the second hot pressing roller (17) and the horizontal plane of the conveyor belt of the conveyor belt assembly (11) is the height of a single PET foam substrate.

6. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The rotation speed of the second hot pressing roller (17) is equal to the transmission speed of the prepreg coil, and the speed at which the conveyor belt assembly (11) transmits the PET foam substrate is equal to the transmission speed of the prepreg coil, that is, the transmission speed of the prepreg coil, the rotation speed of the second hot pressing roller (17), and the transmission speed of the PET foam substrate are all 3-8 cm / s.

7. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The first hot pressing roller (14) is a hot steel roller, and the roller surface temperature is 80-98°C; The second hot pressing roller (17) is a fluororubber roller, and the roller surface temperature is 105-120°C; The third hot pressing roller (19) is a polytetrafluoroethylene composite roller, which comprises a heat-conducting polytetrafluoroethylene outer layer and a steel inner roller, the heat-conducting polytetrafluoroethylene outer layer has a thermal conductivity of 0.5-2.0 W / m·K, and the roller surface temperature of the polytetrafluoroethylene composite roller is 145-180° C.; The leveling roller (100) is a fluororubber roller, and the roller surface temperature is at room temperature.

8. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 2, characterized in that: The laser scanning and heating component (16) comprises a first screw (161), a screw drive motor (162), and a laser emitter (163) that moves axially along the first screw (161); the scanning speed of the laser emitter (163) is 0.2-2.0 m / s, the laser scanning power is 200-500 W, and the surface temperature of the composite prepreg tape after laser scanning is 180-240° C.

9. The automated production system for processing reinforced foam core materials for wind turbine blades according to claim 1, characterized in that: The FPET Block heat treatment subsystem (2) comprises a semi-finished FPET Block conveyor belt assembly (21), an oven (22), and a hot pressing roller group (23). The oven (22) is arranged on the semi-finished FPET Block conveyor belt assembly (21), and the semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly (21) is transferred to the oven (22) for heat treatment; the hot pressing roller group (23) is arranged in the oven (22), and specifically, the hot pressing roller group (23) comprises a plurality of hot pressing rollers (24) rotatably arranged in the oven (22), the central axes of all the hot pressing rollers (24) are in the same horizontal plane, and the vertical distance between the roller surface of a single hot pressing roller (24) and the conveyor belt surface in the semi-finished FPET Block conveyor belt assembly (21) is equal to that of the finished standard FPET Block. The heat-pressing rollers (24) in the heat-pressing roller group (23) are all fluororubber rollers; and the ambient temperature in the oven (22) is set at 80-90°C.

10. An automated production system for processing reinforced foam core materials for wind turbine blades according to claim 9, characterized in that: The transmission speed of the semi-finished FPET Block on the semi-finished FPET Block transmission belt assembly (21) is equal to the heat transmission speed of the PET foam substrate in the PET foam substrate hot pressing subsystem (1) or the heat transmission speed of n stacks of PET foam substrates.

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