Wind power blade and wind power blade forming method

Abstract

The invention relates to the field of wind power blades, and discloses a wind power blade and a wind power blade forming method.The wind power blade comprises a blade body, a plurality of drainage gushing channels and a leeside shell formed on the blade body and arranged in a blade tip area, the drainage gushing channels comprise a plurality of drainage pipes, and the drainage pipes and the extension direction of the blade body form an angle; the drainage pipe is pre-buried in the leeside shell, penetrates through the leeside shell and is used for communicating the inner cavity with the external environment. The wind turbine blade is used for solving the problem that a drainage pipe is prone to being blocked, the drainage pipe is pre-buried in a leeside shell, damage to the wind turbine blade structure caused by drilling after the wind turbine blade is formed is avoided, and the overall strength and integrity of the wind turbine blade are improved; the drainage pipes can be replaced after being blocked and failing, the maintenance cost is low, particles are effectively dispersed through the multiple drainage pipes under the condition that the size of the drainage gushing channel is not changed, and the blocking risk is reduced.

Description

Technical Field

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

[0002] During the operation of wind turbine blades, liquids such as rainwater and dew will adhere to their surfaces. If these liquids are not removed in time, they will accumulate on the blades, increase the weight of the blades, and then increase wind resistance, reducing the speed and power generation efficiency of the wind turbine. In thunderstorm seasons or special climatic conditions, water may accumulate inside the blades due to thermal expansion and contraction. If this accumulated water cannot be discharged in time, it will not only increase the weight of the blades, but may also damage the structure and performance of the blades, and even affect the stability of the entire wind turbine. In order to drain the blades, drainage holes are generally set at the tip of the blades to prevent water from accumulating inside the blades.

[0003] Existing drainage holes are easily clogged by particles in the inner cavity of wind turbine blades, which makes it impossible for water vapor inside the blades to be discharged, thereby affecting the service life of the blades. Summary of the invention

[0004] The embodiments of the present application provide a wind turbine blade and a wind turbine blade forming method, which can disperse particulate matter through multiple drainage pipes, reduce the risk of blockage, and increase the service life of the blade.

[0005] On the one hand, an embodiment of the present application provides a wind turbine blade, comprising: a blade body, comprising a blade tip area and a blade root area arranged relatively to each other along the length direction, the blade body comprising a windward surface shell, a leeward surface shell and an inner cavity formed by the windward surface shell and the leeward surface shell; a plurality of drainage channels formed in the leeward surface shell and placed in the blade tip area, the drainage channels comprising a plurality of drainage pipes arranged at an angle to the extension direction of the blade body, the drainage pipes being pre-buried in the leeward surface shell and passing through the leeward surface shell for connecting the inner cavity with the external environment.

[0006] According to the wind turbine blade provided in the embodiment of the present application, the drainage pipe includes a first diameter section and a second diameter section with different inner diameters, and the first diameter section and the second diameter section are alternately arranged.

[0007] According to the wind turbine blade provided in the embodiment of the present application, the drainage pipe includes two first diameter sections disposed at two ends of the second diameter section in the length direction, one first diameter section is communicated with the inner cavity, and the other first diameter section is communicated with the external environment;

[0008] The inner diameter of the first diameter section is at least twice the inner diameter of the second diameter section.

[0009] According to the wind turbine blade provided in the embodiment of the present application, the material of the drainage pipe is polyvinyl chloride, and the expansion coefficient ranges from 1.5 to 2 per meter per degree Celsius.

[0010] On the other hand, an embodiment of the present application provides a method for forming a wind turbine blade, comprising:

[0011] Providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade, with a drainage pipe inserted along a preset trajectory, wherein the preset trajectory forms a preset angle with the extending direction of the layer structure assembly;

[0012] Blocking both ends of the drainage pipe, pouring the base material of the blade into the leeward shell mold, and solidifying the blade;

[0013] The obstructions at both ends of the drain pipe and the leeward shell mold are removed to form a leeward shell of a wind turbine blade.

[0014] According to the wind turbine blade forming method provided in an embodiment of the present application, the step of preparing the layer structure assembly with the drainage pipe inserted along a preset trajectory formed in the leeward shell mold of the wind turbine blade includes:

[0015] Providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade, with a through hole opened along a preset trajectory, wherein the through hole is arranged through the layer structure assembly;

[0016] Insert the drain pipe into the through hole.

[0017] According to the wind turbine blade forming method provided in the embodiment of the present application, the layer structure assembly with through holes opened along a preset trajectory formed in the leeward shell mold of the wind turbine blade is prepared, comprising:

[0018] Laying a layer structure assembly on a leeward shell mold of a wind turbine blade;

[0019] A through hole is provided on the layer structure assembly along a preset track.

[0020] According to the wind turbine blade forming method provided in the embodiment of the present application, the layer structure assembly provided in the leeward surface shell mold of the wind turbine blade with through holes opened along a preset trajectory comprises:

[0021] Providing a plurality of wind turbine blade thickness cloths with splicing holes opened along a preset trajectory, wherein the splicing holes are arranged through the thickness cloth;

[0022] A plurality of the thickness cloths are stacked and laid on the leeward shell mold in a preset order to form a layer structure assembly, and a plurality of the splicing holes are connected in sequence to form a through hole.

[0023] According to the wind turbine blade forming method provided in the embodiment of the present application, the layer structure assembly with a drainage pipe inserted along a preset trajectory formed in the leeward shell mold of the wind turbine blade comprises:

[0024] Provide multiple thickness cloths for wind turbine blades and multiple matching splicing tubes;

[0025] A plurality of the thickness cloths are stacked and arranged in a stacked manner in the shell mold of the leeward side of the wind turbine blade and are respectively plugged and matched with the plurality of the splicing tubes along a preset trajectory, wherein the plurality of the thickness cloths are stacked and arranged in a stacked manner to form a layer structure assembly, and the plurality of the splicing tubes are connected to form a drainage pipe.

[0026] According to the wind turbine blade forming method provided in the embodiment of the present application, the plurality of thickness cloths stacked and respectively plugged and matched with the plurality of splicing tubes along the preset tracks are formed in the wind turbine blade leeward shell mold, comprising:

[0027] Inserting a plurality of the splicing tubes into a plurality of the thickness cloths respectively along a preset track;

[0028] A plurality of the thickness cloths are stacked and laid in a preset order in the leeward shell mold.

[0029] According to the wind turbine blade forming method provided in the embodiment of the present application, the plurality of thickness cloths stacked and respectively plugged and matched with the plurality of splicing tubes along the preset tracks are formed in the wind turbine blade leeward shell mold, comprising:

[0030] Laying a first section of thick cloth with a first section of splicing holes opened along a preset trajectory on a leeward shell mold of a wind turbine blade;

[0031] Insert the first section of the splicing pipe into the first section of the splicing hole;

[0032] Laying a second section of thick cloth with a second section of splicing holes opened along the preset track on the first section of thick cloth;

[0033] Insert the second section of the splicing pipe into the second section of the splicing hole, and connect the second section of the splicing pipe with the first section of the splicing pipe;

[0034] Laying the N-th thickness cloth with the N-th thickness hole opened along the preset track on the N-1-th thickness cloth;

[0035] Insert the Nth section splicing tube into the Nth section splicing hole, and connect the Nth section splicing tube with the N-1th section splicing tube.

[0036] The wind turbine blades and the wind turbine blade forming method of the embodiments of the present application are provided with a plurality of drainage channels in the blade tip area of ​​the leeward shell body for discharging water vapor in the inner cavity of the blade body, and the drainage pipes are pre-buried in the leeward shell body to avoid damage to the wind turbine blade structure caused by drilling after the wind turbine blades are formed, thereby improving the overall strength and integrity of the wind turbine blades, and also avoiding direct friction of particles on the wind turbine blades, thereby protecting the wind turbine blades and extending the service life of the wind turbine blades; the drainage pipes can be replaced after failure, with low maintenance costs, and multiple drainage pipes can effectively disperse the particles, and when the size of the drainage channels remains unchanged, the entry of large particles is effectively avoided, thereby reducing the risk of blockage. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solution of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0038] Figure 1 A schematic diagram of the structure of a wind turbine blade provided by some embodiments of the present application is shown;

[0039] Figure 2 A partial cross-sectional view of a blade tip region of a leeward shell provided in some embodiments of the present application is shown;

[0040] Figure 3 A schematic cross-sectional view of a drain pipe according to some embodiments of the present application is shown;

[0041] Figure 4 A schematic cross-sectional view showing a drain pipe penetrating a leeward shell in some embodiments of the present application;

[0042] Figure 5 One of the schematic flow diagrams of the wind turbine blade forming method according to some embodiments of the present application is shown;

[0043] Figure 6 A second schematic flow chart of a wind turbine blade forming method according to some embodiments of the present application is shown;

[0044] Figure 7 A third flow chart of a wind turbine blade forming method according to some embodiments of the present application is shown;

[0045] Figure 8 A fourth flow chart of a wind turbine blade forming method according to some embodiments of the present application is shown;

[0046] Fig. 9 A fifth flow chart showing a method for forming a wind turbine blade according to some embodiments of the present application;

[0047] Fig.10A sixth flow chart showing a method for forming a wind turbine blade according to some embodiments of the present application;

[0048] Fig.11 FIG7 shows a seventh flow chart of a method for forming a wind turbine blade according to some embodiments of the present application.

[0049] Reference numerals:

[0050] 100: blade body; 101: windward shell; 102: leeward shell; 103: blade root area; 104: blade tip area; 105: inner cavity; 110: cloth layer; 111: inner skin layer; 112: outer skin layer; 200: drainage channel; 201: drainage pipe; 210: first diameter section; 220: second diameter section; Y: extension direction. DETAILED DESCRIPTION

[0051] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain the present application, rather than to limit the present application. For those skilled in the art, the present application can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present application by illustrating the examples of the present application.

[0052] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the statement "include..." do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0053] Water accumulates in the inner cavity of a wind turbine blade due to condensation or direct liquid inflow, and must be drained. If the water cannot be drained, there is a risk that the water will freeze in winter and damage or destroy the wind turbine blade by expanding when it freezes. Another potential risk is that due to a lightning strike in the tip area of ​​the wind turbine blade, the accumulated water suddenly evaporates, which can also damage or destroy the rotor blade. Therefore, a drainage hole is provided in the tip area of ​​the wind turbine blade, which connects the inner side of the wind turbine blade and the outer side thereof so that water can flow out.

[0054] However, during the production and manufacturing process of the blades, there may be some tiny particles left inside the blades, such as metal shavings, sand, etc. Or, during the operation of the wind turbine, dust, particles, etc. in the environment may penetrate into the blades through the gaps or holes in the blades. And there are also cases where particles are produced by internal wear of the blades. These particles will cause the drainage holes to be blocked, making the drainage holes ineffective, resulting in the inability to discharge the water vapor in the inner cavity of the blades, which will be affected by the environmental climate, lightning, etc., and affect the life of the blades.

[0055] In order to solve the problems in the prior art, the embodiments of the present application provide a wind turbine blade and a method for forming a wind turbine blade. The wind turbine blade provided by the embodiments of the present application is first introduced below.

[0056] like Figure 1 and Figure 2 As shown, an embodiment of the present application provides a wind turbine blade including: a blade body 100 including a blade tip area 104 and a blade root area 103 arranged relatively to each other along the length direction, the blade body 100 including a windward surface shell 101, a leeward surface shell 102 and an inner cavity 105 formed by the windward surface shell 101 and the leeward surface shell 102; a plurality of drainage channels 200 are formed in the leeward surface shell 102 and are placed in the blade tip area 104, the drainage channels 200 include a plurality of drainage pipes 201 arranged at an angle A to an extension direction Y of the blade body 100, the drainage pipes 201 are pre-buried in the leeward surface shell 102, and penetrate the leeward surface shell 102, for connecting the inner cavity 105 with the external environment.

[0057] Among them, the layer structure assembly includes multiple cloth layers 110, core materials and main beams stacked and laid in the thickness direction in the leeward shell 102 mold, and the cloth layers 110 are extended and laid along the length direction of the leeward shell 102 mold. Specifically, the cloth layers 110 include an outer skin layer 112, an inner skin layer 111 and a decreasing layer placed between the outer skin layer 112 and the inner skin layer 111.

[0058] The drainage channel 200 is provided in the blade tip area 104, and the water in the inner cavity 105 receives a larger centrifugal force, which is more conducive to draining the water in the inner cavity 105. The drainage channel is provided in the leeward shell 102, and because the air pressure in the leeward shell 102 is relatively low, the water in the inner cavity 105 is easier to flow out under the action of the pressure difference.

[0059] The drainage channel 200 is formed by pre-embedding the drainage pipe 201 in the leeward shell 102. First, the pre-embedding method can reduce the irreversible damage to the leeward shell 102 caused by the subsequent opening, which affects the strength and integrity of the leeward shell 102. In addition, during the water discharge process, the water contacts and rubs against the drainage pipe 201, and when there are particles in the inner cavity 105, the particles contact and rub against the drainage pipe 201, which prevents the particles and water from directly contacting the leeward shell 102, thereby protecting the leeward shell 102.

[0060] In addition, when the particulate matter blocks the drain pipe 201 and causes the drain pipe 201 to fail, the blockage problem can be solved by removing the drain pipe 201 and replacing it with other pipes.

[0061] In the embodiment of the present application, the drainage channel 200 may be provided with multiple drainage pipes 201, and the multiple drainage pipes 201 may effectively disperse the distribution of particles, and prevent a large number of small particles from gathering in one drainage pipe 201, causing accumulation and blocking the drainage pipe 201. In addition, the multiple drainage pipes 201 may be subdivided for the drainage channel 200 of limited size, so as to prevent large particles from entering the drainage pipe 201 and reduce the risk of blockage. For example, each drainage channel 200 includes at least 10 drainage pipes 201.

[0062] For another example, the diameter of each drainage channel 200 is 8 mm, and the diameter of a single drainage pipe 201 can be 3 mm. During the pre-embedding process, a through hole with a diameter of 8 mm can be opened along the thickness direction of the layer structure assembly of the leeward shell 102, and multiple drainage pipes 201 with a diameter of 3 mm are placed in the through hole. During the pouring process of the leeward shell 102, the matrix material is poured between adjacent drainage pipes 201 and between the drainage pipes 201 and the layer structure assembly. After curing, the drainage pipe 201 and the layer structure assembly are connected and fixed. For example, the inner surface roughness of the drainage pipe 201 is less than Ra8, and the wall thickness is 100-200 μm.

[0063] Or, if Figure 3 As shown, a plurality of through holes spaced apart from each other are provided along the thickness direction of the layer structure assembly of the leeward shell 102, and the drain pipe 201 is inserted into the through hole. The circumscribed figure of the cross section of the plurality of drain pipes 201 is a circle, and the diameter of the circle is 8 mm, i.e., the range of a single drainage channel 200. During the pouring process of the leeward shell 102, the matrix material is poured between the drain pipe 201 and the layer structure assembly, and after curing, the drain pipe 201 and the layer structure assembly are connected and fixed.

[0064] In other embodiments of the present application, continue to refer to Figure 2The drainage channel 200 forms an acute angle, such as 45 degrees, with the extension direction Y of the blade body 100 from the blade root area 103 to the blade tip area 104, so that the water vapor in the inner cavity 105 is more easily drained out.

[0065] In addition, in other embodiments of the present application, the wind turbine blade includes at least two drainage channels 200 spaced apart along the extension direction Y of the blade body 100. For example, the wind turbine blade has three drainage channels 200. After one of the drainage channels 200 is blocked, the other drainage channels 200 can still ensure that the water vapor in the inner cavity 105 is drained out in time. In addition, multiple drainage channels 200 improve the drainage efficiency.

[0066] Furthermore, in an embodiment of the present application, the material of the drain pipe 201 is polyvinyl chloride, and the expansion coefficient ranges from 1.5 to 2 per meter per degree Celsius. This is beneficial for the inner diameter of the drain pipe 201 to expand after the temperature rises, which is more conducive to the discharge of water vapor from the inner cavity 105. For example, when the temperature of the drain pipe 201 is greater than 40°C, the inner diameter of the drain pipe 201 expands, and its internal space will increase accordingly, thereby reducing the possibility of water vapor accumulation in the pipe. At the same time, the contact area between the inner wall of the expanded pipe and the water flow will also increase, which is conducive to the evaporation and discharge of water vapor. This is to prevent pipe blockage and keep drainage unobstructed.

[0067] Polyvinyl chloride (PVC) is a waterproof plastic material with excellent physical and chemical properties, such as corrosion resistance, weather resistance, and insulation.

[0068] In some optional embodiments of the present application, the drain pipe 201 includes a first diameter section 210 and a second diameter section 220 with different inner diameters, and the first diameter section 210 and the second diameter section 220 are alternately arranged.

[0069] First, when the water flows through the first diameter section 210 with a smaller inner diameter, due to the increase in flow velocity (according to Bernoulli's principle, the flow velocity is inversely proportional to the cross-sectional area of ​​the pipe), the suspended particles and impurities in the water flow will be subjected to a greater scouring force, and thus are more likely to be carried away by the water flow rather than being deposited at the bottom of the drain pipe 201.

[0070] When the water flows into the second diameter section 220 with a larger inner diameter, the flow rate will be slowed down accordingly. Most of the particles have been taken away due to the scouring effect of the first diameter section 210, so the number of particles deposited in the second diameter section 220 will be relatively small. In addition, the larger inner diameter also provides more space for bubbles in the water flow to rise and burst, releasing the gas therein, which helps to reduce blockage caused by gas accumulation.

[0071] More importantly, the alternating arrangement of the first diameter section 210 and the second diameter section 220 forms a plurality of "contraction-expansion" flow channel structures inside the drainage pipe 201. When water flows through these structures, eddy and turbulent effects are generated, which can further wash away the sediment on the inner wall of the pipe and prevent it from accumulating and forming blockages.

[0072] Specifically, Figure 4 As shown, in an optional embodiment of the present application, the drain pipe 201 includes two first diameter sections 210 disposed at both ends of the second diameter section 220 in the length direction, one first diameter section 210 is connected to the inner cavity 105, and the other first diameter section 210 is connected to the external environment; wherein the inner diameter of the first diameter section 210 is at least twice the inner diameter of the second diameter section 220. For example, the inner diameter of the first diameter section 210 is 3 mm, and the inner diameter of the second diameter section 220 is 1 mm.

[0073] When the inner diameter of the first diameter section 210 is much larger than the second diameter section 220, the water flow will experience a significant change in flow rate when entering or leaving the first diameter section 210 through the second diameter section 220. Specifically, when the water flow enters the second diameter section 220 from the first diameter section 210, the flow rate will increase (because the cross-sectional area is reduced), and this increased flow rate helps to flush out impurities and particles that may be deposited in the second diameter section 220. On the contrary, when the water flow enters the first diameter section 210 from the second diameter section 220, the flow rate will slow down, but because the inner diameter of the first diameter section 210 is large enough, even if the flow rate slows down, it is unlikely to cause serious blockage.

[0074] In addition, in another embodiment of the present application, the drain pipe 201 includes two second diameter sections 220 disposed at both ends of the first diameter section 210 in the length direction, one second diameter section 220 is connected to the inner cavity 105, and the other second diameter section 220 is connected to the external environment. The inner diameter of the first diameter section 210 is greater than the inner diameter of the second diameter section 220.

[0075] The second diameter section 220 with a small inner diameter is placed at both ends of the first diameter section 210 with a large inner diameter, which can effectively prevent large particles in the inner cavity 105 from entering the drain pipe 201 and causing blockage of the drain pipe 201. It also reduces the risk of large particles in the external environment accidentally entering the drain pipe 201 and then entering the inner cavity 105, causing damage to the inner cavity 105 and affecting the operation of the wind turbine blades.

[0076] Some embodiments of the present application also provide a wind turbine blade forming method, which is used to form the wind turbine blades provided in the above embodiments, such as Figure 5 As shown, a method for forming a wind turbine blade includes steps S1 to S3.

[0077] S1: providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade and having a drainage pipe inserted along a preset trajectory, wherein the preset trajectory and an extension direction of the layer structure assembly form a preset angle.

[0078] Among them, the leeward shell mold is an important tool for forming the leeward shell of the wind turbine blade. It is usually made of high-strength and high-wear-resistant materials, such as steel or special alloys, to ensure the durability and precision of the mold. The structural design of the mold needs to accurately match the shape of the windward side of the blade. Of course, there is also a corresponding leeward shell mold for forming the leeward shell. After the leeward shell is formed in the leeward shell mold, the leeward shell is formed in the leeward shell mold, and then the two molds are relatively buckled to achieve the bonding of the leeward shell and the leeward shell to form a complete wind turbine blade.

[0079] The layer structure assembly includes multiple cloth layers, core materials and main beams stacked and laid in the leeward shell mold in the thickness direction, and the cloth layers are extended and laid along the length direction of the leeward shell mold. Specifically, the cloth layers include an outer skin layer, an inner skin layer and a decreasing layer placed between the outer skin layer and the inner skin layer. The drain pipe is inserted and penetrates the layer structure assembly along a preset trajectory, and forms a preset angle with the extension direction of the layer structure assembly. For example, the preset angle is an acute angle, which is conducive to the liquid in the inner cavity to flow out of the drain pipe. In other words, the drain pipe is pre-buried in the layer structure assembly at a preset angle, and penetrates the layer structure assembly to connect the inner cavity of the leeward shell with the outside. Since the main beam is the main force-bearing component of the shell, in order to ensure the integrity of the main beam, the drain pipe is installed to avoid the main beam position.

[0080] In addition, a plurality of drainage pipes parallel to each other can be pre-buried along a preset track in the layer structure assembly.

[0081] S2: Block both ends of the drain pipe, pour the base material of the blade into the leeward shell mold, and solidify it.

[0082] In order to prevent the matrix material from entering the drain pipe during the pouring process, the two openings of the drain pipe are detachably blocked. Then the matrix material is poured into the leeward shell mold to bond the various parts of the blade together to form a strong overall structure and provide the necessary strength and stability after curing. Among them, the matrix material includes any resin such as epoxy resin, vinyl ester resin, unsaturated polyester resin and hardener.

[0083] For example, the infusion system is arranged before infusion, and infusion points, vents and runner systems are installed in the leeward shell mold to control the flow of the matrix material and gas discharge to ensure uniform distribution of the matrix material. The leeward shell mold is wrapped with a vacuum bag and evacuated to remove bubbles to ensure close contact and structural strength of the materials during the infusion process. Specialized mixing equipment is used to accurately mix the resin and hardener to form the matrix material, stir evenly, and monitor the mixing temperature and time to ensure material performance. The matrix material is slowly injected from the root of the blade or a specially designed infusion point to control the infusion speed and avoid turbulence and bubbles. During the infusion process, temperature sensors and visual monitoring are used to track the position of the resin front to ensure that the matrix material evenly fills all parts of the blade.

[0084] After the matrix material is fully injected, the vacuum state is maintained to allow the matrix material to fully cure at a specific temperature. This process may take several hours to dozens of hours, depending on the characteristics of the matrix material and the curing conditions. The curing progress of the matrix material is tracked by monitoring equipment such as temperature sensors to ensure that the curing process proceeds smoothly.

[0085] Before step S2, the auxiliary beams, blade root embedded parts and other structures of the wind turbine blade need to be installed and laid, and then the matrix material is poured.

[0086] S3: removing the obstructions at both ends of the drain pipe and the leeward shell mold to form the leeward shell of the wind turbine blade.

[0087] Specifically, after curing is completed, remove the blockages, vacuum bags and flow channel systems at both ends of the drain pipe and prepare for subsequent processing. Check the surface and internal quality of the blade and repair any defects found. The repair process may include steps such as grinding, filling, and painting. Carefully remove the leeward shell of the wind turbine blade from the mold and conduct a comprehensive quality inspection. The inspection content includes the normality of the internal drain pipe, the appearance, size, and strength test of the shell, etc., to ensure that the leeward shell of the wind turbine blade meets the design standards.

[0088] By forming a leeward shell with a drainage pipe, the drainage channel is pre-buried. The pre-buried method can make the diameter of the drainage pipe as small as possible, reduce the blockage of the drainage pipe by large particles, and avoid irreversible damage to the wind turbine blade shell caused by secondary drilling in the later stage.

[0089] like Figure 6 As shown, in one embodiment of the present application, the step of preparing the layer structure assembly with the drainage pipe inserted along a preset trajectory formed in the leeward shell mold of the wind turbine blade in the above step S1 includes the following steps S11 and S12.

[0090] S11: providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade and having through holes formed along a preset trajectory, wherein the through holes are arranged throughout the entire layer structure assembly.

[0091] The through hole penetrates the inner skin and the outer skin of the layer structure assembly, wherein the inner skin is used to enclose the inner cavity of the blade, and the outer skin is used to contact the external environment. The opening of the through hole facilitates the subsequent insertion of the drainage pipe. The position of the through hole can also be located by a preset mark in the leeward shell mold, and the mark can be a notch or a protrusion.

[0092] In addition, the through hole can be a straight hole of a full diameter or a variable diameter hole, which is opened based on the outer diameter of the pre-installed drainage pipe.

[0093] S12: Insert the drain pipe into the through hole.

[0094] The drain pipe is inserted into the through hole adapted thereto, so that the drain pipe is pre-buried in the layer structure assembly. The outer wall of the drain pipe fits tightly with the layer structure assembly, so that after the pouring is completed, the matrix material solidifies between the drain pipe and the layer structure assembly, playing the role of bonding and fixing the drain pipe and the layer structure assembly.

[0095] like Figure 7 As shown, in a specific embodiment of the present application, the layer structure assembly with through holes opened along a preset trajectory formed in the leeward shell mold of the wind turbine blade in the above step S11 includes steps S111 and S112.

[0096] S111: Laying a layer structure assembly on a leeward shell mold of a wind turbine blade.

[0097] In order to improve the molding efficiency and ensure the accuracy of the preset angle between the drain pipe and the layer structure assembly, the layer structure assembly can be completely laid on the leeward shell mold first.

[0098] Specifically, ensure the cleanliness and accuracy of the leeward shell mold, check whether there are defects or foreign matter on the mold surface, and repair and clean it if necessary. Prepare the required laying materials, such as fiberglass cloth (fiberglass cloth), resin, foam core material (such as balsa wood, PVC or PET foam), etc.

[0099] Lay the release agent on the mold, and lay the outer skin layer and the decreasing layer of glass cloth from the root to the tip of the blade, ensuring that each layer is laid evenly, tightly, without bubbles and wrinkles. During the laying process, the number and thickness of the glass cloth can be adjusted as needed to meet the strength and stiffness requirements of the blade. Install the main beam in the middle of the blade. The main beam is equivalent to the "spine" of the blade and plays a vital role in the support and stability of the blade. Ensure that the main beam is installed accurately and firmly, and there is no gap between the mold and the glass cloth. Lay the foam core material at different positions inside the mold to enhance the stiffness and stability of the blade. Lay UD cloth and other reinforcing materials at key positions such as the trailing edge of the mold to improve the local strength and stiffness of the blade. Lay the inner skin layer and the decreasing layer of glass cloth from the root to the tip of the blade, ensuring that each layer is laid evenly, tightly, without bubbles and wrinkles. To complete the laying of the layer structure assembly.

[0100] S112: Opening a through hole along a preset trajectory on the layer structure assembly.

[0101] Through the hole-opening device, a through hole is opened from the inner skin layer to the outer skin layer along a preset trajectory. If the through hole is a variable diameter hole, holes of different diameters can be opened in sequence and opening depth by hole-opening devices of different diameters, and the holes are connected to each other to realize the insertion of the drainage pipe, wherein the drainage pipe can be inserted once or inserted and connected separately in multiple times.

[0102] For example, the drain pipe is a variable diameter pipe, including a first diameter section and a second diameter section, the first diameter section is facing away from the second diameter section and close to the inner cavity, and the diameter of the first diameter section is larger than the diameter of the second diameter section. A through hole with the diameter of the second diameter section is opened on the layer structure assembly along a preset trajectory using a hole opening device, and then the through hole of the second diameter section is expanded to the diameter of the first diameter section within a first preset depth to form a through hole. Then the variable diameter drain pipe is inserted into the through hole.

[0103] like Figure 8 As shown, in another specific embodiment of the present application, the layer structure assembly with through holes opened along a preset trajectory formed in the leeward shell mold of the wind turbine blade in the above step S11 includes steps S113 and S114.

[0104] S113: providing a thickness cloth of a plurality of wind turbine blades with splicing holes opened along a preset trajectory, wherein the splicing holes are arranged through the thickness cloth.

[0105] In order to reduce the difficulty of opening through holes in the layer structure assembly, the layer structure assembly is opened multiple times. The pre-laid thickness cloth is pre-opened with splicing holes along a preset track, wherein the thickness cloth can be a single-layer fiber cloth, or a multi-layer fiber cloth, or a component including a fiber cloth and a core material.

[0106] S114: Laying multiple thickness cloths on the leeward shell mold in a preset order to form a layer structure assembly, and connecting multiple splicing holes in sequence to form a through hole.

[0107] When laying multiple layers of thickness cloth, the connectivity of the splicing holes and the preset angle with the extension direction of the cloth layer should be ensured, so that the through hole finally formed forms a preset angle with the extension direction of the cloth layer. For example, by setting a detachable columnar or tubular mark on the leeward shell mold, the splicing holes of the thickness cloth are laid through the mark on the leeward shell mold, and after the layer structure assembly is laid, the mark is removed and the drain pipe is inserted, which reduces the difficulty of laying the layer structure assembly and improves the accuracy of the preset angle of the drain pipe.

[0108] In addition, if Fig. 9 As shown, in some other embodiments of the present application, the above step S1 provides a layer structure assembly with a drainage pipe inserted along a preset trajectory formed in the leeward shell mold of the wind turbine blade, including steps S4 and S5.

[0109] S4: Provide multiple thickness cloths for wind turbine blades and multiple matching splicing tubes.

[0110] Specifically, the multi-layer fabric layers of the layer structure assembly are divided into a plurality of thickness fabrics with a certain thickness. The drainage pipe is divided into a plurality of splicing pipes of a certain length matching the thickness of the thickness fabric. This facilitates assembly when molding the layer structure assembly, thereby improving the molding efficiency of the blade shell.

[0111] S5: forming a plurality of thickness cloths stacked and respectively plugged into and matched with a plurality of splicing tubes along a preset track in a shell mold of the leeward surface of the wind turbine blade, wherein the plurality of thickness cloths stacked and respectively plugged into and matched with a plurality of splicing tubes along a preset track, wherein the plurality of thickness cloths stacked and respectively formed a layer structure assembly, and the plurality of splicing tubes were connected to form a drainage pipe.

[0112] That is to say, in the layer structure assembly formed in the leeward shell mold, the drain pipe is spliced ​​in multiple sections, and the thickness cloths laid in sequence are plugged with splicing pipes of matching lengths, and the splicing pipes are connected in sequence to form a drain pipe. Among them, the splicing pipes can be bonded by gluing the ports, and the chambers of the splicing pipes are connected to each other after bonding. Of course, adjacent splicing pipes can also be plugged in with interference fit to achieve connection and penetration, so as to prevent the matrix material from entering the interior of the splicing pipes and causing blockage during the subsequent pouring process.

[0113] The method of assembling a structure of multiple thickness fabrics and multiple spliced ​​tube forming layers is beneficial to the design of a drainage pipe with multiple sections of variable diameters. Figure 4The variable diameter structure of the drainage pipe shown can be realized by arranging splicing pipes of different diameters in different thicknesses, and this method can realize the design of more variable diameter sections of the drainage pipe. During the molding process using this method, there may be a certain angle between adjacent splicing pipes, making the entire drainage pipe wavy.

[0114] like Fig.10 As shown, in other embodiments of the present application, in the above step S5, a plurality of thickness cloths which are stacked and respectively plugged into and matched with a plurality of splicing tubes along preset tracks are formed in the leeward shell mold of the wind turbine blade, including steps S51 and S52.

[0115] S51: inserting a plurality of splicing tubes into cloths of a plurality of thicknesses along a preset track respectively.

[0116] That is, a splicing hole corresponding to the splicing tube is opened along a preset track on the thickness cloth, and then the splicing tube is inserted into the splicing hole to complete the installation of the splicing tube. The thicknesses of the plurality of thickness cloths can be the same or different. In order to improve the connection stability between the splicing tube and the thickness cloth, the splicing tube and the thickness cloth can also be bonded with glue for pre-fixation.

[0117] S52: Laying a plurality of thickness cloths in a preset order in a stacked manner into the leeward shell mold.

[0118] The thickness cloth with splicing tubes is laid in sequence. During the laying process, the positions of adjacent splicing tubes are ensured to be relative and connected.

[0119] like Fig.11 As shown, in other embodiments of the present application, in the above step S4, a plurality of thickness cloths which are stacked and respectively plugged into and matched with a plurality of splicing tubes along preset tracks are formed in the leeward shell mold of the wind turbine blade, including steps S53 to S58.

[0120] S53: Laying a first-section thick cloth having a first-section splicing hole opened along a preset trajectory on the leeward shell mold of the wind turbine blade.

[0121] S54: Insert the first section of the splicing pipe into the first section of the splicing hole.

[0122] Specifically, the plurality of thickness cloths of the layer structure assembly are defined as the first section thickness cloth, the second section thickness cloth, ... the N-1 section thickness cloth, and the N section thickness cloth in the order of laying. The splicing holes opened on the corresponding thickness cloths are defined as the first section splicing hole, the second section splicing hole, ... the N-1 section splicing hole, and the N section splicing hole. The plurality of splicing tubes corresponding to the thickness cloths are defined as the first section splicing tube, the second section splicing tube, ... the N-1 section splicing tube, and the N section splicing tube.

[0123] The first section of the thickness cloth is laid on the leeward shell mold, a first section of the splicing hole is opened along a preset track based on the mark on the leeward shell mold, the first section of the splicing tube is inserted into the first section of the splicing hole, and the first section of the splicing tube and the extension direction of the first section of the thickness cloth are at a preset angle. Of course, the first section of the thickness cloth can also be opened with a first section of the splicing hole, and then the first section of the thickness cloth is laid on the leeward shell mold.

[0124] S55: Laying a second section of thickness cloth with a second section of splicing holes opened along a preset track on the first section of thickness cloth.

[0125] S56: inserting the second section of the splicing pipe into the second section of the splicing hole, and connecting the second section of the splicing pipe with the first section of the splicing pipe.

[0126] The second section of the thick cloth can be laid on the first section of the thick cloth. Then, the second section of the splicing hole is opened along the preset track based on the position of the first splicing hole, which can improve the accuracy of the position of the second section of the splicing hole. The second section of the splicing tube is inserted into the second section of the splicing hole, the second section of the splicing tube is connected to the end of the first section of the splicing tube, and the inner cavity is made conductive.

[0127] S57: Laying the Nth section thickness cloth with the Nth section splicing hole opened along the preset track on the N-1th section thickness cloth.

[0128] S58: Insert the Nth section of the splicing pipe into the Nth section of the splicing hole, and connect the Nth section of the splicing pipe with the N-1th section of the splicing pipe.

[0129] According to steps S57 and S58, the last section of the thickness cloth with the splicing hole is laid on the previous section of the thickness cloth, and the last section of the splicing pipe is inserted into the splicing hole to complete the connection of the splicing pipe. The above method of laying, opening holes and inserting pipes can ensure that the angle between the drainage pipe and the extension direction of the layer structure assembly is more accurate, and when problems occur, adjustments can be made more timely and accurately.

[0130] The above is only a specific implementation of the present application. Those skilled in the art can clearly understand that for the convenience and simplicity of description, the specific working processes of the systems, modules and units described above can refer to the corresponding processes in the aforementioned method embodiments, and will not be repeated here. It should be understood that the protection scope of the present application is not limited to this. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed in this application, and these modifications or replacements should be included in the protection scope of this application.

Claims

1. A wind turbine blade, characterized in that: include: A blade body, comprising a blade tip region and a blade root region arranged opposite to each other along the length direction, wherein the blade body comprises a windward surface shell, a leeward surface shell and an inner cavity formed by the windward surface shell and the leeward surface shell; A plurality of drainage channels are formed in the leeward shell and are placed in the blade tip area. The drainage channels include a plurality of drainage pipes arranged at an angle to the extension direction of the blade body. The drainage pipes are pre-buried in the leeward shell and penetrate the leeward shell to connect the inner cavity with the external environment.

2. The wind turbine blade according to claim 1, characterized in that: The drainage pipe comprises a first diameter section and a second diameter section with different inner diameters, and the first diameter section and the second diameter section are alternately arranged.

3. The wind turbine blade according to claim 2, characterized in that: The drainage pipe comprises two first diameter sections disposed at two ends of the second diameter section in the length direction, one of the first diameter sections is communicated with the inner cavity, and the other first diameter section is communicated with the external environment; The inner diameter of the first diameter section is at least twice the inner diameter of the second diameter section.

4. The wind turbine blade according to claim 1, characterized in that: The material of the drainage pipe is polyvinyl chloride, and the expansion coefficient ranges from 1.5 to 2 per meter per degree Celsius.

5. A method for forming a wind turbine blade, characterized in that: include: Providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade, with a drainage pipe inserted along a preset trajectory, wherein the preset trajectory forms a preset angle with the extending direction of the layer structure assembly; Blocking both ends of the drainage pipe, pouring the base material of the blade into the leeward shell mold, and solidifying the blade; The obstructions at both ends of the drain pipe and the leeward shell mold are removed to form a leeward shell of a wind turbine blade.

6. The method for forming a wind turbine blade according to claim 5, characterized in that: The step of preparing the layer structure assembly formed in the mold of the leeward shell of the wind turbine blade and having the drain pipe inserted along a preset trajectory comprises: Providing a layer structure assembly formed in a shell mold of the leeward surface of a wind turbine blade, with a through hole opened along a preset trajectory, wherein the through hole is arranged through the layer structure assembly; Insert the drain pipe into the through hole.

7. The method for forming a wind turbine blade according to claim 6, characterized in that: The method of preparing the layer structure assembly with through holes formed along a preset trajectory in the shell mold of the leeward surface of the wind turbine blade comprises: Laying a layer structure assembly on a leeward shell mold of a wind turbine blade; A through hole is provided on the layer structure assembly along a preset track.

8. The method for forming a wind turbine blade according to claim 6, characterized in that: The layer structure assembly provided in the mold of the shell body on the leeward side of the wind turbine blade and having through holes opened along a preset trajectory comprises: Providing a plurality of wind turbine blade thickness cloths with splicing holes opened along a preset trajectory, wherein the splicing holes are arranged through the thickness cloth; A plurality of the thickness cloths are stacked and laid on the leeward shell mold in a preset order to form a layer structure assembly, and a plurality of the splicing holes are connected in sequence to form a through hole.

9. The method for forming a wind turbine blade according to claim 5, characterized in that: The layer structure assembly provided in the shell mold of the leeward surface of the wind turbine blade and having the drain pipe inserted along a preset trajectory comprises: Provide multiple thickness cloths for wind turbine blades and multiple matching splicing tubes; A plurality of the thickness cloths are stacked and arranged in a stacked manner in the shell mold of the leeward side of the wind turbine blade and are respectively plugged and matched with the plurality of the splicing tubes along a preset trajectory, wherein the plurality of the thickness cloths are stacked and arranged in a stacked manner to form a layer structure assembly, and the plurality of the splicing tubes are connected to form a drainage pipe.

10. The method for forming a wind turbine blade according to claim 9, characterized in that: The plurality of thick cloths stacked and arranged in a layer in the shell mold of the leeward surface of the wind turbine blade and respectively plugged and matched with the plurality of splicing tubes along the preset tracks include: Inserting a plurality of the splicing tubes into a plurality of the thickness cloths respectively along a preset track; A plurality of the thickness cloths are stacked and laid in a preset order in the leeward shell mold.

11. The method for forming a wind turbine blade according to claim 9, characterized in that: The plurality of thick cloths stacked and arranged in a layer in the shell mold of the leeward surface of the wind turbine blade and respectively plugged and matched with the plurality of splicing tubes along the preset tracks include: Laying a first section of thick cloth with a first section of splicing holes opened along a preset trajectory on a leeward shell mold of a wind turbine blade; Insert the first section of the splicing pipe into the first section of the splicing hole; Laying a second section of thick cloth with a second section of splicing holes opened along the preset track on the first section of thick cloth; Insert the second section of the splicing pipe into the second section of the splicing hole, and connect the second section of the splicing pipe with the first section of the splicing pipe; Laying the N-th thickness cloth with the N-th thickness hole opened along the preset track on the N-1-th thickness cloth; Insert the Nth section splicing tube into the Nth section splicing hole, and connect the Nth section splicing tube with the N-1th section splicing tube.

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