An automated production system for processing reinforced foamed core materials for wind turbine blades

Abstract

This application relates to the field of production equipment for auxiliary materials of fan blades, in particular to an automated production system for processing reinforced foamed cores for fan blades, which includes several hot pressing subsystems for PET foamed substrates and an FPET Block heat treatment subsystem. Through several hot pressing subsystems for PET foamed substrates, semi-finished FPET Blocks are produced in batches and continuously. The semi-finished FPET Blocks are heat-treated by the FPET Block heat treatment subsystem to obtain finished standard FPET Blocks. The finished standard FPET Blocks are vertically cut and trimmed along the y-axis direction to obtain PET foamed composite core base materials. The obtained PET foamed composite core base materials are grooved, punched, edge-cut and trimmed, and polished to obtain reinforced foamed cores. This application can mass-produce high-quality PET foamed composite cores for fan blades, reducing the total production cost of fan blades.

Description

Technical Field

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

[0002] The quality of fan blades has an important impact on the safety of wind power equipment and power generation efficiency. It is one of the most basic and highest-cost components of wind turbines. The core components of fan blades include main beams, trailing edge beams, webs, and shells. The fan 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 rigid closed-cell foam polymer material, such as PET foam material, PVC foam material, etc.

[0003] Since the reinforced core material requires good shear strength, 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 two PET foam substrates that need to be hot-pressed and compounded to a molten state, and then perform hot pressing and compounding on the two PET foam substrates to obtain a two-layer PET foam substrate. Heat the surface of the two-layer PET foam substrate that needs to be hot-pressed and compounded with another PET foam substrate to a molten state, and then perform hot pressing and compounding on the two-layer PET foam substrate and the other PET foam substrate to obtain a three-layer PET foam substrate. Repeat the above operations to obtain an (n + 1)-layer PET foam substrate, which is the finished product FPET Block. Then, perform vertical edge cutting and trimming on the obtained FPET Block along the y-axis direction to obtain the reinforced core material. The obtained reinforced core material is grooved, drilled, edge-cut and trimmed, and polished according to the design requirements of the fan blade to obtain the finished reinforced core material.

[0004] It is found through research that in the above existing production mode of the reinforced core material, the production efficiency of the reinforced core material is relatively low, resulting in a relatively high total production cost of the fan blade, 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, this application provides an automated production system for processing reinforced foam core materials for fan blades.

[0006] The automated production system for processing reinforced foam core materials for fan blades provided by this application is achieved through the following technical solutions:

[0007] An automated production system for processing reinforced foamed core materials for wind turbine blades, comprising a plurality of PET foamed substrate hot pressing subsystems and an FPET Block heat treatment subsystem. Through a plurality of PET foamed substrate hot pressing subsystems, batch and continuous production is achieved to obtain semi-finished FPET Blocks. The obtained semi-finished FPET Blocks are heat treated through the FPET Block heat treatment subsystem to obtain finished standard FPET Blocks. The finished standard FPET Blocks are vertically cut and trimmed along the y-axis direction to obtain PET foamed composite core material substrates. The obtained PET foamed composite core material substrates are grooved, punched, edge cut and trimmed, and polished to obtain reinforced foamed core materials for wind turbine blades;

[0008] The PET foamed substrate hot pressing subsystems are marked as n. The PET foamed substrate hot pressing subsystem at the starting end is marked as n = Number.ONE. The PET foamed substrate hot pressing subsystem at the starting end hot presses the PET foamed substrate / prepreg / PET foamed substrate into a two-layer PET foamed substrate. The PET foamed substrate hot pressing subsystem downstream of the PET foamed substrate hot pressing subsystem at the starting end is marked as Number.TWO, which hot presses the two-layer PET foamed substrate / prepreg / PET foamed substrate into a three-layer PET foamed substrate. It can be seen from this that the PET foamed substrate hot pressing subsystem is marked as n, and the n-layer PET foamed substrate / prepreg / PET foamed substrate is hot pressed into an n + 1-layer PET foamed substrate. When n = Number.ONE, one layer of PET foamed substrate is the PET foamed substrate. The n + 1-layer PET foamed substrate output by the PET foamed substrate hot pressing subsystem at the end is the semi-finished FPET Block. The obtained semi-finished FPET Block is input into the downstream FPET Block heat treatment subsystem for heat treatment to obtain the finished standard FPET Block; The thickness of the reinforced foamed core material for wind turbine blades depends on the vertical cutting method along the y-axis direction, and the length of the reinforced foamed core material for wind turbine blades depends on the number of PET foamed substrates hot pressed and stacked in the n + 1-layer PET foamed substrate.

[0009] This application can mass-produce high-quality PET foamed 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.

[0010] Preferably, the single PET foam substrate hot pressing subsystem includes a conveyor belt assembly, a prepreg tape coil storage roller, a first release paper peeling roller, a first hot pressing roller, a first release paper recycling roller, a laser scanning 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. The prepreg tape coil storage roller winds a prepreg tape coil. The operation process of the PET foam substrate hot pressing subsystem is as follows: After the prepreg tape coil passes through the first release paper peeling roller, the first release paper is peeled off. The surface of the prepreg tape from which the first release paper has been peeled is melted by the laser emitted by the laser scanning heating assembly and then transmitted to the first hot pressing roller. The prepreg tape from which the first release paper has been peeled is hot press-compounded with the PET foam substrate or n stacks of PET foam substrates transported by the conveyor belt assembly. While the prepreg tape is hot press-compounded with the PET foam substrate or n stacks of PET foam substrates, the second release paper is separated at the second hot pressing roller and recycled to the second release paper recycling roller. Subsequently, the PET foam substrate or n stacks of PET foam substrates with the hot-pressed prepreg tape on the upper surface output by the second hot pressing roller are input into the third hot pressing roller. The third hot pressing roller performs a hot pressing and melting treatment on the upper surface of the prepreg tape to facilitate the hot press-compounding of the prepreg tape with another PET foam substrate, and then it is input into the PET foam substrate handling assembly. At this time, the conveyor belt assembly stops. The PET foam substrate handling assembly clamps and hot presses another PET foam substrate onto the upper surface of the PET foam substrate or n stacks of PET foam substrates with the hot-pressed prepreg tape on the upper surface to form a two-stack PET foam board or an n + 1-stack PET foam board. Then the conveyor belt assembly starts. The obtained two-stack PET foam board or n + 1-stack PET foam board is input into the leveling roller for hot pressing and leveling treatment. The two-stack PET foam board or n + 1-stack PET foam board after the hot pressing and leveling treatment is input into the next PET foam substrate hot pressing subsystem for the production of a three-stack PET foam board or an n + 2-stack PET foam board. Through continuous production by several PET foam substrate hot pressing subsystems, a semi-finished product FPET Block can be obtained.

[0011] Preferably, the central axes of the prepreg tape coil storage roller and the first release paper recycling roller are in the same plane perpendicular to the horizontal plane. The central axes of the first hot pressing roller and the first release paper peeling roller are in the same plane perpendicular to the horizontal plane, and the first hot pressing roller is located directly above the first release paper peeling roller. Moreover, the distance between the first hot pressing roller and the first release paper peeling roller is equal to 0.98 - 1.00 times the thickness of the prepreg tape coil.

[0012] Preferably, the laser scanning 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.

[0013] Preferably, the central axes of the second hot pressing roller and the second release paper recycling roller are in the same plane 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 for handling the PET foam substrate, and hot pressing one PET foam substrate onto n stacks of PET foam substrates with prepreg tape 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.

[0014] Preferably, the rotation speed of the second hot pressing roller is equal to the conveying speed of the prepreg tape coil, and the conveying speed of the conveyor belt assembly for the PET foam substrate is equal to the conveying speed of the prepreg tape coil, that is, the conveying speed of the prepreg tape coil, the rotation speed of the second hot pressing roller, and the conveying speed of the PET foam substrate are all 3 - 8 cm / s.

[0015] Preferably, the first hot pressing roller is a hot steel roller with a roller surface temperature of 80 - 98 °C;

[0016] Preferably, the second hot pressing roller is a fluororubber roller with a roller surface temperature of 105 - 120 °C;

[0017] Preferably, the third hot pressing roller is a polytetrafluoroethylene composite roller, which includes a heat-conducting polytetrafluoroethylene outer layer and a steel inner roller. The heat conduction coefficient of the heat-conducting 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;

[0018] Preferably, the leveling roller is a fluororubber roller with a roller surface temperature at room temperature.

[0019] Preferably, the laser scanning heating assembly includes a first lead screw, a lead screw driving motor, and a laser emitter moving along the axial direction of the first lead 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.

[0020] 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 transported into the oven for heat treatment. The hot pressing roller group is arranged in the oven. Specifically, the hot pressing roller group includes several hot pressing rollers rotatably arranged in the oven. The central axes of all the hot pressing rollers are in the same horizontal plane. The vertical distance between the 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. All the hot pressing rollers in the hot pressing roller group are fluororubber rollers. The ambient temperature in the oven is set to 80 - 90 °C.

[0021] Preferably, the transmission speed of the semi-finished FPET Block on the conveyor belt assembly is equal to the transmission speed of the PET foam substrate in the PET foam substrate hot pressing subsystem or the transmission speed of n stacks of PET foam substrates.

[0022] In summary, the present application has the following advantages:

[0023] 1. The present invention can mass-produce high-quality PET foam composite cores 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.

[0024] 2. The present invention can mass-produce high-quality PET foam composite cores for wind turbine blades when used with the supporting prepreg tape coil, and at the same time can improve the mechanical strength and service life of the prepared PET foam composite core.

[0025] 3. The present invention can improve the mechanical strength and service life of the prepared PET foam composite core by optimizing the process parameters, ensure the production efficiency and reduce the total production cost of wind turbine blades at the same time. Brief Description of the Drawings

[0026] Figure 1 is a simplified production process diagram of the automated production system for processing the reinforced foam core for wind turbine blades in the embodiment.

[0027] Figure 2 is a detailed production display diagram of the automated production system for processing the reinforced foam core for wind turbine blades in the embodiment.

[0028] Figure 3 is a structural schematic diagram of the PET foam substrate hot pressing subsystem in the embodiment.

[0029] Figure 4It is a schematic structural diagram of a laser scanning heating component in a hot pressing subsystem of a PET foaming substrate.

[0030] Figure 5 It is a schematic structural diagram of an FPET Block heat treatment subsystem in the embodiment.

[0031] Figure 6 It is a schematic structural diagram of a handling component for a PET foaming substrate in the embodiment.

[0032] Figure 7 It is a schematic structural diagram of a jaw component of a handling component for a PET foaming substrate in the embodiment.

[0033] In the figure, 1 is a hot pressing subsystem of a PET foaming substrate; 10 is a handling component for a PET foaming substrate; 101 is a support base; 102 is a crossbar component; 1020 is an electric push cylinder A; 1021 is a support slide bar; 1022 is a sliding lead screw; 1023 is a stepping motor; 103 is a jaw component; 1031 is a connecting piece; 1032 is a main pipe A; 1033 is a sliding pipe A; 10331 is a limiting ring; 1034 is a first cylinder; 1035 is a platform plate; 1036 is a second cylinder; 1037 is a suction disc; 10371 is a laser emitter B; 10372 is a rubber pad; 1038 is a clamping jaw arm; 10381 is a main pipe B; 10382 is a sliding pipe B; 10383 is a limiting ring piece; 10384 is a third cylinder; 1039 is a fixture; 10391 is a rectangular bearing block; 10392 is a fourth cylinder; 10393 is a positioning cone; 100 is a leveling roller; 11 is a conveyor belt component; 12 is a pre-impregnated tape coil storage roller; 13 is a first release paper peeling roller; 14 is a first hot pressing roller; 15 is a first release paper recycling roller; 16 is a laser scanning heating component; 161 is a first lead screw; 162 is a lead screw drive motor; 163 is a laser emitter; 17 is a second hot pressing roller; 18 is a second release paper recycling roller; 19 is a third hot pressing roller; 2 is an FPET Block heat treatment subsystem; 21 is a semi-finished FPET Block conveyor belt component; 22 is an oven; 23 is a hot pressing roller set; 24 is a hot pressing roller. Detailed implementation manners

[0034] To further understand the present invention, the preferred implementation manners will be described below in combination with embodiments and drawings.

[0035] Reference Figure 1-2, an automated production system for processing reinforced foamed core materials for wind turbine blades includes several PET foamed substrate hot pressing subsystems 1 and one FPET Block heat treatment subsystem 2. Several PET foamed substrates and prepregs pass through several PET foamed substrate hot pressing subsystems 1 for continuous hot pressing and lamination to form semi-finished FPET Blocks, achieving batch and continuous production of semi-finished FPET Blocks. And the obtained semi-finished FPET Blocks are heat treated by 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 foamed core materials for wind turbine blades. After edge grinding the obtained semi-finished reinforced foamed core materials for wind turbine blades, a rough product of the PET foamed composite core material substrate is obtained. By grooving, punching, edge cutting and leveling, and polishing the obtained rough product of the PET foamed composite core material substrate, the finished product of the reinforced foamed core material for wind turbine blades can be obtained.

[0036] The prepreg is a thermoplastic glass fiber prepreg, and the matrix impregnating resin is selected as PET. Preferably, the prepreg is a self-made composite prepreg. The PET foamed composite core material produced in cooperation with the composite prepreg has relatively good mechanical strength and service life, and at the same time improves the overall production efficiency.

[0037] Reference Figure 1-2, the specific production operation is 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 presses the PET foam substrate / prepreg tape / PET foam substrate to form a two-layer PET foam substrate; The PET foam substrate hot pressing subsystem 1 downstream of the PET foam substrate hot pressing subsystem 1 at the starting end is marked as Number.TWO. The PET foam substrate hot pressing subsystem 1 downstream of the PET foam substrate hot pressing subsystem 1 at the starting end hot presses the two-layer PET foam substrate / prepreg tape / PET foam substrate to form a three-layer PET foam substrate; The PET foam substrate hot pressing subsystem 1 downstream is marked as Number.THREE, which hot presses the three-layer PET foam substrate / prepreg tape / PET foam substrate to form a four-layer PET foam substrate,... It can be seen from this: The PET foam substrate hot pressing subsystem 1 is marked as n, which hot presses the n-layer PET foam substrate / prepreg tape / PET foam substrate to form an n + 1-layer PET foam substrate; When n = Number.ONE, the 1-layer PET foam substrate is the PET foam substrate; The n + 1-layer PET foam substrate output by the PET foam substrate hot pressing subsystem 1 at the end is the semi-finished product FPETBlock. 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 product standard FPET Block.

[0038] The current size of the PET foam substrate used in the reinforced foam core material for wind turbine blades is 1200 mm in length, 1000 mm in width, and 50 mm in height.

[0039] The size of the reinforced foam core material for wind turbine blades can be flexibly designed. The size of the classic reinforced foam core material for wind turbine blades, that is, the general-purpose reinforced foam core material for wind turbine blades, is 1200 mm in length, 1000 ± 10 mm in width, and 50 mm in height. That is, 20 PET foam substrates and 19 prepreg tapes are continuously hot pressed and compounded through 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.

[0040] The thickness of the reinforced foam core material for wind turbine blades depends on the vertical cutting method along the y-axis direction, and the length of the reinforced foam core material for wind turbine blades depends on the number of PET foam substrates hot pressed and stacked in the n + 1-layer PET foam substrate.

[0041] Taking the finished product of the classical reinforced foamed core material for fan blades as an example, a cutting machine is used to perform vertical cutting along the y-axis direction to obtain the reinforced foamed core material for fan blades with a thickness of 50 mm. Producing the above-mentioned finished product of the classical reinforced foamed core material for fan blades requires 19 PET foamed substrate hot pressing subsystems 1 and 1 FPET Block heat treatment subsystem 2.

[0042] Reference Figure 3 , a single PET foamed substrate hot pressing subsystem 1 includes a conveyor belt assembly 11, a prepreg roll storage roller 12, a first release paper peeling roller 13, a first hot pressing roller 14, a first release paper recycling roller 15, a laser scanning heating assembly 16, a second hot pressing roller 17, a second release paper recycling roller 18, a third hot pressing roller 19, a leveling roller 100, and a PET foamed substrate handling assembly 10. The prepreg roll storage roller 12 winds up the prepreg roll.

[0043] The structure of the prepreg roll is as follows: The prepreg roll includes several adjacent and spaced prepregs, and a first release paper and a second release paper laminated on the upper and lower surfaces of the prepreg. The spacing between adjacent prepregs is equal to the spacing between adjacent PET foamed substrates. On the premise of ensuring that the transmission speed of the prepreg roll is equal to the transmission speed of the PET foamed substrate, the continuous hot pressing and lamination operation of the PET foamed substrate hot pressing subsystem 1 can be ensured.

[0044] Reference Figure 3 , the laser scanning heating assembly 16 is arranged 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 foamed substrate and the prepreg. 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 foamed substrate and the prepreg.

[0045] Reference Figure 3 , the central axes of the prepreg roll storage roller 12 and the first release paper recycling roller 15 are in the same plane perpendicular to the horizontal plane. And the central axes of the first hot pressing roller 14 and the first release paper peeling roller 13 are in the same plane perpendicular to the horizontal plane. The first hot pressing roller 14 is located downstream of the prepreg roll storage roller 12, and the first hot pressing roller 14 is directly above the first release paper peeling roller 13. The first hot pressing roller 14 is a hot steel roller, and the surface temperature of the roller is 80 - 98 °C. The first hot pressing roller 14, i.e., the hot steel roller, preheats the prepreg to facilitate subsequent hot pressing operations.

[0046] Reference Figure 3, the distance between the first hot press 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 distance between the first hot press roller 14 and the first release paper peeling roller 13 is equal to 1 times the thickness of the prepreg tape coil.

[0047] Reference Figure 3 , the laser scanning heating component 16 is located downstream of the first release paper peeling roller 13 and upstream of the second hot press roller 17, that is, the laser scanning heating component 16 is installed between the first release paper peeling roller 13 and the second hot press roller 17.

[0048] Reference Figure 3-4 , specifically, the laser scanning heating component 16 rotates and is fixedly connected to the first lead screw 161 on the bracket, the lead screw drive motor 162 fixedly connected to the bracket for driving the first lead screw 161 to rotate around its own axis, and the laser emitter 163 moving along the axial direction of the first lead screw 161. The line-plane angle formed by the laser emitted by the laser emitter 163 and the prepreg tape is 45 - 135°.

[0049] Preferably, the line-plane angle formed by the laser emitted by the laser emitter 163 and the composite prepreg tape is 90°.

[0050] 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.

[0051] Preferably, the scanning speed of the laser emitter 163 is 1.0 ± 0.05 m / s, and the operating set scanning speed of the laser emitter 163 is 1 m / s. The preferred range of the laser scanning power is 300 - 400 W, and the operating set laser scanning power of the laser emitter 163 is 360 W.

[0052] 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 foaming substrate.

[0053] Reference Figure 3 , the second hot press roller 17 is located downstream of the laser scanning heating component 16. The central axes of the second hot press roller 17 and the second release paper recycling roller 18 are in the same plane perpendicular to the horizontal plane. The second hot press roller 17 is a fluororubber roller, and the roller surface temperature is 105 - 120 °C.

[0054] Reference Figure 3, the third hot press roller 19 is located downstream of the second hot press roller 17, and the vertical distance between the third hot press 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 foamed substrate and the prepreg tape. Preferably, the vertical distance between the third hot press 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 foamed substrate and the prepreg tape.

[0055] Reference Figure 3 , the third hot press roller 19 is a polytetrafluoroethylene composite roller, and the polytetrafluoroethylene composite roller includes a heat-conducting polytetrafluoroethylene outer layer and a steel inner roller. The heat conduction coefficient of the heat-conducting 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. The third hot press roller 19 can perform a melting heating treatment on the prepreg tape, which is convenient for subsequent hot pressing and laminating another PET foamed substrate at the PET foamed substrate handling assembly 10. Moreover, when implementing the melting heating treatment, the material of the polytetrafluoroethylene composite roller does not affect bonding and has good peelability.

[0056] Reference Figure 3 , the PET foamed substrate handling assembly 10 is arranged between the third hot press roller 19 and the leveling roller 100, and is used to handle the PET foamed substrate, and hot press one PET foamed substrate onto n stacks of PET foamed substrates with prepreg tapes to form n + 1 stacks of PET foamed substrates.

[0057] The PET foamed substrate handling assembly 10 can be selected as a commercially available handling robotic arm.

[0058] Preferably, a PET foamed substrate handling assembly 10 with a specific structure is adopted. Reference Figure 3 And Figure 6 , the PET foamed 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 jaw 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 own length direction. The crossbar assembly 102 is fixedly connected to an electric push cylinder A1020. The electric push cylinder A1020 is fixedly connected to the support base 101, and 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 to adjust the clamping height of the jaw assembly 103. The jaw assembly 103 moves left and right on the crossbar assembly 102 to clamp and transport the PET foamed substrate to a designated position on the conveyor belt of the conveyor belt assembly 11.

[0059] Reference Figure 6-7, the crossbar assembly 102 includes two support slide bars 1021 and a sliding lead screw 1022 fixedly and rotatably connected to the two support slide bars 1021. One end of the sliding lead screw 1022 rotatably penetrates through a support slide bar 1021 and is located outside the bottom surface of the support slide bar 1021. The sliding lead screw 1022 located outside the bottom surface of the support slide bar 1021 is fixedly connected to a stepping motor 1023 through a coupling. The stepping motor 1023 drives the sliding lead screw 1022 to rotate around its own axis, so that the jaw assembly 103 moves left and right on the sliding lead screw 1022.

[0060] Reference Figure 6-7 , the jaw assembly 103 includes a connecting member 1031 threadedly connected to the sliding lead screw 1022. The lower surface of the connecting member 1031 is fixedly connected to a main pipe A1032. 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 axially symmetric 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 circumferential 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 disc 1035 is fixedly connected to the bottom surface of the sliding pipe A1033. Two axially symmetric second cylinders 1036 are fixedly connected to the upper surface of the platform disc 1035. The push rod of the second cylinder 1036 penetrates through and is slidably connected to the platform disc 1035, and the push rod of the second cylinder 1036 is fixedly connected to a suction disc 1037.

[0061] Reference Figure 6-7 , a laser emitter 10371 is fixedly connected to the center of the upper surface of the suction disc 1037. The emitting end of the laser emitter 10371 penetrates through the suction disc 1037 and is located outside the center of the lower surface of the suction disc 1037. The height of the part of the emitting end of the laser emitter 10371 exposed outside the suction disc 1037 is 1 mm. That is, the center of the PET foam substrate is positioned by laser to improve the accuracy of clamping and the overall production efficiency. A rubber pad 10372 with a thickness of 1.2 - 1.5 mm is fixedly connected to the bottom surface of the suction disc 1037. A nano adhesive layer is fixedly connected to the bottom surface of the rubber pad 10372. A plurality of clamping jaw arms 1038 are detachably and fixedly connected to the periphery of the platform disc 1035.

[0062] Reference Figure 6-7, the clamping jaw arm 1038 includes a main pipe B10381, and a sliding pipe B10382 is slidably connected inside the main pipe B10381. A limiting ring piece 10383 is fixedly connected to the outer wall of the sliding pipe B10382. A third air cylinder 10384 is fixedly connected to the outer wall of the main pipe B10381. The push rod of the third air cylinder 10384 is fixedly connected to the circumferential side of the limiting ring piece 10383, that is, the third air cylinder 10384 can drive the sliding pipe B10382 to slide up and down inside the main pipe B10381. One end of the clamping jaw arm 1038 is detachably and fixedly connected to the circumferential side of the platform disk 1035, and the other end is detachably and fixedly connected with a fixture 1039, that is, the bottom of the sliding pipe B10382 is detachably and fixedly connected with the fixture 1039.

[0063] Reference Figure 6-7 , the fixture 1039 includes a cuboid bearing block 10391, a fourth air cylinder 10392, and a positioning cone 10393. The cuboid bearing block 10391 is detachably and fixedly connected to the bottom of the sliding pipe B10382, and the cuboid bearing block 10391 is perpendicular to the horizontal plane. The fourth air cylinder 10392 is fixedly connected to the outer side surface of the cuboid bearing block 10391. The push rod of the fourth air cylinder 10392 slidably penetrates the cuboid bearing block 10391 and is located on the inner side of the inner side surface of the cuboid bearing block 10391. The positioning cone 10393 is fixedly connected to the surface of the push rod of the fourth air cylinder 10392 that slidably penetrates the cuboid bearing block 10391, and the fourth air cylinder 10392 pushes the positioning cone 10393 to move in the horizontal direction to clamp the PET foam substrate.

[0064] Reference Figure 6-7 , the third air cylinder 10384 can drive the sliding pipe B10382 to slide up and down inside the main pipe B10381 to adjust the position of the positioning cone 10393, so that the clamping point of the positioning cone 10393 is positioned at the side center of the PET foam substrate, improving the overall clamping and transportation stability of the clamping jaw arm 1038.

[0065] Reference Figure 6-7 , the specific connection method between the clamping jaw arm 1038 and the platform disk 1035: Two circular ring disks A are fixedly connected to the outer wall of the platform disk 1035 and the two circular ring disks A are arranged coaxially at intervals. One end of the main pipe B10381 of the clamping jaw arm 1038 is fixedly connected with a circular ring disk B, and the circular ring disk B is coaxially arranged between the two circular ring disks A. Fixing screws are passed through the two circular ring disks A and the circular ring disk B. After adjusting the inclination angle of the clamping jaw arm 1038, the fixing screws are screwed with nuts, and the clamping jaw arm 1038 can be fixedly connected to the platform disk 1035. In order to adapt to the length of the PET foam substrate, it is only necessary to adjust the inclination angle of the clamping jaw arm 1038 and the outward sliding distance of the sliding pipe B10382, which can meet the processing and production of non-standard PET foam substrates.

[0066] Reference Figure 6-7 The specific connection method between the fixture 1039 and the sliding tube B10382 on the clamping jaw arm 1038: At the other end of the main tube B10381 of the clamping jaw arm 1038, two circular disk bodies C are fixedly connected. The two circular disk bodies C are arranged coaxially at intervals. A circular disk body D is fixedly connected to the upper surface of the rectangular parallelepiped bearing block 10391. The circular disk body D is coaxially arranged between the two circular disk bodies C. The two circular disk bodies C and the circular disk body D are penetrated by fixing screws. Adjust the rectangular parallelepiped bearing block 10391 to be perpendicular to the horizontal plane, and screw on the nuts for the fixing screws, then the fixture 1039 can be detachably and fixedly connected to the clamping jaw arm 1038.

[0067] Reference Figure 3 The leveling roller 100 is located downstream of the PET foamed substrate handling assembly 10, and performs hot pressing and leveling treatment on the n + 1 stacked PET foamed substrates output by the PET foamed substrate handling assembly 10. The leveling roller 100 is a fluororubber roller, and the roller surface temperature is at room temperature. The height difference between the vertical distance from the leveling roller 100 to the horizontal plane of the conveyor belt of the conveyor belt assembly 11 and the vertical distance from the second hot pressing roller 17 to the horizontal plane of the conveyor belt of the conveyor belt assembly 11 is the height of a single PET foamed substrate, which can ensure that a single PET foamed substrate is hot-pressed and laminated by the single PET foamed substrate hot pressing and laminating subsystem.

[0068] Reference Figure 1-2, the operation process of the hot pressing sub-system 1 of the PET foam substrate is as follows: After the prepreg tape coil passes through the first release paper peeling roller 13, the first release paper is peeled off. The surface of the prepreg tape with the first release paper peeled off is melted by the laser emitted from the laser scanning heating component 16 and then transported to the first hot pressing roller 14. The prepreg tape with the first release paper peeled off is hot press-compounded with the transported PET foam substrate or n stacks of PET foam substrates of the transport belt assembly 11. While the prepreg tape is hot press-compounded with the PET foam substrate or n stacks of PET foam substrates, the second release paper is separated at the second hot pressing roller 17, and the second release paper is recycled to the second release paper recycling roller 18. Subsequently, the PET foam substrate or n stacks of PET foam substrates with the upper surface hot pressed with the prepreg tape output by the second hot pressing roller 17 are input into the third hot pressing roller 19. The third hot pressing roller 19 performs a hot pressing and melting treatment on the upper surface of the prepreg tape to facilitate the hot press compounding of the prepreg tape with another PET foam substrate, and then it is input into the PET foam substrate handling assembly 10. At this time, the transport belt assembly 11 stops. The PET foam substrate handling assembly 10 clamps and hot presses another PET foam substrate onto the upper surface of the PET foam substrate or n stacks of PET foam substrates with the upper surface hot pressed with the prepreg tape to form a two-stack PET foam board or an n + 1-stack PET foam board. Then the transport belt assembly 11 starts. The obtained two-stack PET foam board or n + 1-stack PET foam board is input into the leveling roller 100 for hot pressing and leveling treatment. The two-stack PET foam board or n + 1-stack PET foam board after the hot pressing and leveling treatment is input into the next PET foam substrate hot pressing sub-system 1 for the production of a three-stack PET foam board or an n + 2-stack PET foam board. Through the continuous production of several PET foam substrate hot pressing sub-systems 1, the semi-finished product FPET Block can be obtained.

[0069] In order to improve production efficiency, a limit frame area is set at the starting end of the transport belt of the PET foam substrate hot pressing sub-system 1 at the starting end. The limit frame area at the starting end of the transport belt needs to load the PET foam substrate. There are two ways to load the PET foam substrate: The first way to load the PET foam substrate is to be carried by the PET foam substrate handling assembly 10, and the second way to load the foam substrate is to manually carry the PET foam substrate.

[0070] For the PET foam substrate hot pressing sub-system 1 other than the PET foam substrate hot pressing sub-system 1 at the starting end, the starting end of the transport belt on the transport belt assembly 11 is divided into an n + 1-stack PET foam board quality inspection area. The operator will perform an appearance inspection on the n + 1-stack PET foam board to judge the quality of the n + 1-stack PET foam board.

[0071] Reference Figure 4, the 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, and the semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly 21 is transported into the oven 22 for heat treatment. The hot pressing roller group 23 is rotatably connected inside the oven 22. Specifically, the hot pressing roller group 23 includes a number 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 surface of a single hot pressing roller 24 and the surface of the conveyor belt 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 surface of a single hot pressing roller 24 and the surface of the conveyor belt in the semi-finished FPET Block conveyor belt assembly 21 is equal to 1 times the height of the finished standard FPET Block.

[0072] The hot pressing rollers 24 in the hot pressing roller group 23 are all fluororubber rollers, and the surface temperature of the hot pressing roller 24 is equal to the temperature inside the oven 22. The ambient temperature inside the oven 22 is set to 80 - 90 °C.

[0073] The length of the oven 22 is controlled to be 4 - 6 m. Preferably, the length of the oven 22 is controlled to be 5 m. The transport speed of the semi-finished FPET Block on the semi-finished FPET Block conveyor belt assembly 21 is equal to the transport speed of the PET foam substrate in the PET foam substrate hot pressing subsystem 1 or the transport speed of n stacks of PET foam substrates.

[0074] The semi-finished FPET Block 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 in the y-axis direction in subsequent processes, improve the yield rate of the vertical cutting process in the y-axis direction, reduce the overall production cost of wind turbine blades, and is conducive to the development and breakthrough of large megawatt wind power generation products.

Claims

1. An automated production system for processing reinforced foamed core materials for wind turbine blades, characterized in that: It includes several hot pressing subsystems (1) for PET foam substrates and an FPET Block heat treatment subsystem (2). Through several of the subsystems (1), mass and continuous production is achieved to obtain a semi-finished FPET Block. The obtained semi-finished FPET Block is heat treated by the FPET Block heat treatment subsystem (2) to obtain a finished standard FPET Block. The finished standard FPET Block is vertically cut and trimmed along the y-axis direction to obtain a PET foam composite core material substrate. The obtained PET foam composite core material substrate is grooved, drilled, edge cut and trimmed, and polished to obtain a reinforced foam core material for a fan blade; The subsystem (1) is marked as n. The subsystem (1) at the starting end is marked n = Number.ONE. The subsystem (1) at the starting end hot presses a PET foam substrate / prepreg tape / PET foam substrate into a two-layer PET foam substrate; the subsystem (1) downstream of the PET foam substrate hot pressing subsystem (1) at the starting end is marked as Number.TWO, and hot presses the two-layer PET foam substrate / prepreg tape / PET foam substrate into a three-layer PET foam substrate; the n + 1 layer PET foam substrate output by the subsystem (1) at the end is the semi-finished FPET Block; Each of the said subsystems (1) includes a conveyor belt assembly (11), a prepreg tape coil storage roller (12), a first release paper peeling roller (13), a first hot pressing roller (14), a first release paper recycling roller (15), a laser scanning heating assembly (16), a second hot pressing roller (17), a second release paper recycling roller (18), a third hot pressing roller (19), a flattening roller (100), and a PET foam substrate handling assembly (10). The prepreg tape coil storage roller (12) winds a prepreg tape coil. The operation process of the subsystem (1) is as follows: After the prepreg tape coil 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 has been peeled is melted by the laser emitted by the laser scanning heating assembly (16) and then transmitted to the second hot pressing roller (17). The prepreg tape from which the first release paper has been peeled is hot press-compounded with the PET foam substrate or n stacked PET foam substrates conveyed by the conveyor belt assembly (11). While the prepreg tape and the PET foam substrate or n stacked PET foam substrates are hot press-compounded, the second release paper is separated at the second hot pressing roller (17) and recycled to the second release paper recycling roller (18). Subsequently, the PET foam substrate or n stacked PET foam substrates with the hot press-prepreg tape on the upper surface output by the second hot pressing roller (17) are input into the third hot pressing roller (19). The third hot pressing roller (19) performs a hot pressing and melting treatment on the upper surface of the prepreg tape to facilitate the hot press-compounding of the prepreg tape with another PET foam substrate, and then it is input into the PET foam substrate handling assembly (10). At this time, the conveyor belt assembly (11) stops. The PET foam substrate handling assembly (10) clamps and hot presses another PET foam substrate onto the upper surface of the PET foam substrate or n stacked PET foam substrates with the hot press-prepreg tape on the upper surface to form a two-stacked PET foam board or an (n + 1)-stacked PET foam board. Then the conveyor belt assembly (11) starts. The obtained two-stacked PET foam board or (n + 1)-stacked PET foam board is input into the flattening roller (100) for hot pressing and flattening treatment. The two-stacked PET foam board or (n + 1)-stacked PET foam board after the hot pressing and flattening treatment is input into the next subsystem (1) for the production of a three-stacked PET foam board or an (n + 2)-stacked PET foam board.

2. An automated production system for processing reinforced foamed core materials for fan blades according to claim 1, characterized in that: The central axes of the prepreg tape coil storage roller (12) and the first release paper recycling roller (15) are in the same plane perpendicular to the horizontal plane. The central axes of the first hot pressing roller (14) and the first release paper peeling roller (13) are in the same plane perpendicular to the horizontal plane. The first hot pressing roller (14) is located directly above the first release paper peeling roller (13). And the distance 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.

3. An automated production system for processing reinforced foamed core materials for fan blades according to claim 1, characterized in that: The laser scanning heating component (16) is disposed 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 assembly (11) is equal to 0.98 - 1.00 times the total thickness of the PET foamed substrate and the prepreg tape.

4. An automated production system for processing reinforced foamed core materials for wind turbine blades according to claim 1, characterized in that: The central axes of the second hot pressing roller (17) and the second release paper recycling roller (18) are in the same plane 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 in the conveyor belt assembly (11) is equal to 0.99 - 1.00 times the total thickness of the PET foamed substrate and the prepreg tape; the PET foamed substrate handling component (10) is disposed between the third hot pressing roller (19) and the flattening roller (100) for handling the PET foamed substrate, and hot pressing one PET foamed substrate onto n stacks of PET foamed substrates with prepreg tapes to form n + 1 stacks of PET foamed substrates; the height difference between the vertical distance between the flattening roller (100) and the horizontal plane of the conveyor belt in the conveyor belt assembly (11) and 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 the height of a single PET foamed substrate.

5. An automated production system for processing an enhanced foamed core material for a fan blade, as claimed in claim 1, wherein: The rotation speed of the second hot pressing roller (17) is equal to the transmission speed of the prepreg tape coil, and the transmission speed of the PET foamed substrate by the conveyor belt assembly (11) is equal to the transmission speed of the prepreg tape coil, that is, the transmission speed of the prepreg tape coil, the rotation speed of the second hot pressing roller (17), and the transmission speed of the PET foamed substrate are all 3 - 8 cm / s.

6. An automated production system for processing an enhanced foamed core material for a wind turbine blade, 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, and the polytetrafluoroethylene composite roller includes a heat-conducting polytetrafluoroethylene outer layer and a steel inner roller. The heat conduction coefficient of the heat-conducting 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; The flattening roller (100) is a fluororubber roller, and the roller surface temperature is at room temperature.

7. An automated production system for processing reinforced foamed core materials for wind turbine blades according to claim 1, characterized in that: The laser scanning heating component (16) includes a first lead screw (161), a lead screw driving motor (162), and a laser emitter (163) moving axially along the first lead 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.

8. An automated production system for processing reinforced foamed core materials for fan blades according to claim 1, characterized in that: The heat treatment subsystem (2) of the FPET Block includes a semi-finished FPET Block conveyor belt assembly (21), an oven (22), and a hot pressing roller set (23). The oven (22) is arranged on the semi-finished FPET Block conveyor belt assembly (21), and the semi-finished FPET Blocks on the semi-finished FPET Block conveyor belt assembly (21) are transported into the oven (22) for heat treatment. The hot pressing roller set (23) is arranged in the oven (22). Specifically, the hot pressing roller set (23) includes a number 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. The vertical distance between the roller surface of a single hot pressing roller (24) and the surface of the conveyor belt 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. The hot pressing rollers (24) in the hot pressing roller set (23) are all fluororubber rollers. The ambient temperature in the oven (22) is set to 80 - 90 °C.

9. An automated production system for processing an enhanced foamed core material for a fan blade, as claimed in claim 8, wherein: The conveying speed of the semi-finished FPET Blocks on the semi-finished FPET Block conveyor belt assembly (21) is equal to the conveying speed of the PET foamed substrate heat in the subsystem (1) or the conveying speed of the heat of n stacked PET foamed substrates.

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